Mercury 92-8M0069603, 92-8M0070979, MerCruiser Diesel Inboard 2.8L, MerCruiser Diesel Inboard 4.2L Maintance Manual

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2.0L

Diesel Engine

Inboard Models

OPERATION &

MAINTENANCE

MANUAL

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Welcome

You have selected one of the finest marine power packages available. It incorporates numerous design features to ensure operating ease and durability.

With proper care and maintenance, you will enjoy using this product for many boating seasons. To ensure maximum performance and carefree use, we ask that you thoroughly read this manual.

The Operation and Maintenance Manual contains specific instructions for using and maintaining your product. We suggest that this manual remain with the product for ready reference whenever you are on the water.

Thank you for purchasing one of our products. We sincerely hope your boating will be pleasant! Mercury Marine, Fond du Lac, Wisconsin, U.S.A.

Name / function:

John Pfeifer, President, Mercury Marine

Read This Manual Thoroughly

IMPORTANT: If you do not understand any portion of this manual, contact your dealer. Your dealer can also provide a demonstration of actual starting and operating procedures.

Notice

Throughout this publication, and on your power package, warnings, cautions, and notices, accompanied by the

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International Hazard Symbol !, may be used to alert the installer and user to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. Observe them carefully.

These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance with these special instructions while performing the service, plus common sense operation, are major accident prevention measures.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

Indicates a situation which, if not avoided, could result in engine or major component failure.

IMPORTANT: Identifies information essential to the successful completion of the task.

NOTE: Indicates information that helps in the understanding of a particular step or action.

IMPORTANT: The operator (driver) is responsible for the correct and safe operation of the boat, the equipment aboard, and the safety of all occupants aboard. We strongly recommend that the operator read this Operation and Maintenance Manual and thoroughly understand the operational instructions for the power package and all related accessories before the boat is used.

WARNING

The engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects or other reproductive harm.

2.0L Diesel Engine Inboard Models

The serial numbers are the manufacturer’s keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

Descriptions and specifications contained herein were in effect at the time this was approved for printing. Mercury Marine, whose policies are based on continuous improvement, reserves the right to discontinue models at any time or to change specifications or designs without notice and without incurring obligation.

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Warranty Message

The product you have purchased comes with a limited warranty from Mercury Marine; the terms of the warranty are set forth in the Warranty Manual included with the product. The Warranty Manual contains a description of what is covered, what is not covered, the duration of coverage, how to best obtain warranty coverage, important disclaimers and limitations of damages, and other related information. Please review this important information.

Copyright and Trademark Information

Alpha, Axius, Bravo One, Bravo Two, Bravo Three, Circle M with Waves Logo, K‑planes, Mariner, MerCathode, MerCruiser, Mercury, Mercury with Waves Logo, Mercury Marine, Mercury Precision Parts, Mercury Propellers, Mercury Racing, MotorGuide, OptiMax, Quicksilver, SeaCore, Skyhook, SmartCraft, Sport‑Jet, Verado, VesselView, Zero Effort, Zeus, #1 On the Water and We're Driven to Win are registered trademarks of Brunswick Corporation. Pro XS is a trademark of Brunswick Corporation. Mercury Product Protection is a registered service mark of Brunswick Corporation.

Identification Records

Please record the following applicable information:

MerCruiser

Engine Model and Horsepower Engine Serial Number

Transom Assembly Serial Number (Sterndrive) Gear Ratio Sterndrive Unit Serial Number

Transmission Model (Inboard) Gear Ratio Transmission Serial Number

Propeller Number Pitch Diameter

Hull Identification Number (HIN) Purchase Date

Boat Manufacturer Boat Model Length

Exhaust Gas Emissions Certification Number (Europe Only)

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Section 1 - Getting to Know Your Power Package

Features and Controls............................................................... 2

Warning Horn Signals......................................................... 2

Instrumentation................................................................... 2

VesselView..................................................................... 2

SmartCraft Speedometer, Tachometer, and Digital

Gauges........................................................................... 2

System Link Digital Gauges........................................... 3

Switches............................................................................. 4

Emergency Stop Switch...................................................... 4

Lanyard Stop Switch........................................................... 5

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition.............................................. 6

Section 2 - On the Water

Safe Boating Recommendations............................................. 12

Carbon Monoxide Exposure.................................................... 13

Be Alert To Carbon Monoxide Poisoning........................... 13

Stay Clear of Exhaust Areas.............................................. 13

Good Ventilation ................................................................ 13

Poor Ventilation ................................................................. 14

Important Operation Information.............................................. 14

Launching......................................................................... 14

Duty Cycle Rating Requirements...................................... 14

High‑Output Rating........................................................... 14

Operation Chart................................................................ 15

Freezing Temperature and Cold Weather Operation....... 15

Drain Plug and Bilge Pump............................................... 16

Starting, Shifting, and Stopping............................................... 16

Before Starting the Engine................................................ 16

Important Information—SmartStart................................... 16

Starting a Cold Engine...................................................... 16

Engine Warm Up.............................................................. 17

Starting a Warm Engine ................................................... 17

Shifting.............................................................................. 17

Engine Shut Down (Stopping).......................................... 17

Protecting People in the Water................................................ 18

Digital Throttle and Shift..................................................... 6

Remote Controls................................................................. 6

Panel Mount Features.................................................... 6

Console Mount Features................................................ 7

Engine Electrical System Overload Protection................... 7

Vessel Integration Panel (VIP) Overload Protection........... 8

Engine Guardian System.................................................... 8

Identification............................................................................... 9

Specifications Label............................................................ 9

Data Label Location............................................................ 9

Engine Data Label.............................................................. 9

Technodrive Transmissions.............................................. 10

While Boat is in Operation.................................................. 18

While the Boat is Stationary............................................... 18

High‑Speed and High‑Performance......................................... 18

Passenger Safety In Pontoon Boats and Deck Boats.............. 18

Boats Having An Open Front Deck.................................... 18

Boats With Front‑Mounted, Raised Pedestal Fishing Seats

........................................................................................... 19

Wave and Wake Jumping........................................................ 19

Impact With Underwater Hazards............................................ 19

Conditions Affecting Operation................................................ 20

Weight Distribution (Passengers and Gear) Inside the

Boat.................................................................................. 20

Bottom of Boat.................................................................. 20

Elevation and Climate....................................................... 20

Propeller Selection............................................................ 21

Getting Started......................................................................... 21

Initial Break‑In Procedure................................................. 21

Engine Break‑In................................................................ 21

20‑Hour Break‑In Period...............................................21

After the 20‑Hour Break‑In Period................................ 21

End of First Season Checkup........................................... 22

Section 3 - Specifications

Fuel Requirements................................................................... 24

Diesel Fuel in Cold Weather.................................................... 24

Antifreeze/Coolant................................................................... 24

Engine Oil................................................................................ 25

Engine Specifications ‑ Inboard Models................................... 25

Fluid Specifications.................................................................. 26

Engine............................................................................... 26

Transmission.................................................................... 26

Approved Paints....................................................................... 26

Section 4 - Maintenance

Owner and Operator Responsibilities...................................... 28

Dealer Responsibilities............................................................ 28

Maintenance............................................................................ 28

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Do‑It‑Yourself Maintenance Suggestions................................ 28

General Inspection................................................................... 28

Engine Cover........................................................................... 29

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Removal.......................................................................... 29

Cleaning.......................................................................... 29

Inspection........................................................................ 29

Installation....................................................................... 29

Maintenance Schedule........................................................... 29

Routine Maintenance...................................................... 29

Scheduled Maintenance.................................................. 30

Engine Oil............................................................................... 31

Specifications.................................................................. 31

Oil Level—Overfilled........................................................ 31

Checking......................................................................... 31

Filling............................................................................... 32

Changing Oil and Filter.................................................... 32

TM 345 Technodrive Transmission Fluid............................... 34

Checking......................................................................... 34

Filling............................................................................... 35

Changing......................................................................... 35

TM 485‑A Technodrive Transmission Fluid............................ 37

Check Fluid..................................................................... 37

Add Fluid......................................................................... 38

Change Fluid................................................................... 38

Engine Coolant....................................................................... 40

Checking and Filling the Closed‑Cooling System........... 40

Draining the Closed‑Cooling System.............................. 42

Air Filter.................................................................................. 43

Removal.......................................................................... 43

Inspection........................................................................ 44

Installation....................................................................... 44

Water‑Separating Fuel Filter.................................................. 45

Draining........................................................................... 45

Replacing........................................................................ 46

Filling............................................................................... 48

Fuel System............................................................................ 49

Priming............................................................................ 49

Filling (Bleeding).............................................................. 49

Fuel Tank Cleaning and Flushing.................................... 49

Seawater System................................................................... 49

Draining the Seawater System........................................ 49

Checking the Seawater Pickups...................................... 51

Cleaning the Seawater Strainer...................................... 51

Engine Seawater Pump Inspection................................. 53

Corrosion Protection............................................................... 53

General Information......................................................... 53

Engine Corrosion Protection Components...................... 53

Removal...................................................................... 53

Cleaning and Inspection............................................. 54

Installation................................................................... 55

Antifouling Paint.............................................................. 55

Lubrication.............................................................................. 55

Throttle Cable.................................................................. 55

Shift Cable....................................................................... 56

Drive Belts.............................................................................. 56

Power‑Assisted Steering Pump Belt Inspection.............. 56

Serpentine Belt Inspection.............................................. 57

Battery.................................................................................... 58

Battery Precautions for Multiple Engines.......................... 58

Section 5 - Storage

Cold Weather (Freezing Temperature), Seasonal Storage, and

Extended Storage................................................................... 62

Cold Weather (Freezing Temperature) Storage.............. 62

Preparing Your Power Package for Seasonal or Extended

Storage............................................................................ 62

Section 6 - Troubleshooting

Diagnosing Electronically Controlled Fuel System

Problems................................................................................ 66

Troubleshooting Charts.......................................................... 66

Starter Motor Will Not Crank Engine, or Cranks Slow..... 66

Engine Will Not Start, or Is Hard to Start......................... 66

Engine Runs Rough, Misses, or Backfires...................... 66

Section 7 - Customer Assistance Information

Owner Service Assistance...................................................... 70

Local Repair Service......................................................... 70

Service Away From Home................................................ 70

Stolen Power Package..................................................... 70

Attention Required After Submersion............................... 70

Replacement Service Parts.............................................. 70

Parts and Accessories Inquiries.................................. 70

Resolving a Problem......................................................... 70

Seasonal Storage............................................................ 63

Extended Storage Instructions........................................ 64

Battery............................................................................. 64

Recommissioning................................................................... 64

Poor Performance........................................................... 66

Incorrect Engine Temperature......................................... 67

Low Engine Oil Pressure................................................. 67

Battery Will Not Charge................................................... 67

Remote Control Operates Hard, Binds, Has Excessive

Free‑play, or Makes Unusual Sounds............................. 67

Contact Information for Mercury Marine Customer Service

.......................................................................................... 71

Customer Service Literature................................................... 71

English Language............................................................. 71

Other Languages.............................................................. 72

Ordering Literature................................................................. 72

United States and Canada................................................ 72

Outside the United States and Canada............................ 72

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Section 8 - Maintenance Log

Scheduled Maintenance Log................................................... 74 Vessel Maintenance Notes...................................................... 75

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Section 1 - Getting to Know Your Power Package

Table of Contents

Features and Controls............................................................ 2

Warning Horn Signals...................................................... 2

Instrumentation................................................................ 2

VesselView .............................................................. 2

SmartCraft Speedometer, Tachometer, and Digital

Gauges .................................................................... 2

System Link Digital Gauges .................................... 3

Switches.......................................................................... 4

Emergency Stop Switch...................................................4

Lanyard Stop Switch........................................................ 5

Keep the Lanyard Stop Switch and Lanyard Cord in

Good Operating Condition ....................................... 6

Digital Throttle and Shift.................................................. 6

Remote Controls.............................................................. 6

Panel Mount Features ............................................. 6

Console Mount Features ......................................... 7

Engine Electrical System Overload Protection................ 7

Vessel Integration Panel (VIP) Overload Protection........ 8

Engine Guardian System................................................. 8

Identification........................................................................... 9

Specifications Label......................................................... 9

Data Label Location......................................................... 9

Engine Data Label........................................................... 9

Technodrive Transmissions........................................... 10

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Features and Controls

Warning Horn Signals

When the key switch is turned to the on position, the horn will turn on for a moment as a test to indicate the horn is working. There are two types of warning horns to alert the operator of an active problem within the engine’s operating system.

Continuous six second beep: Indicates a critical engine condition. Depending on the condition, the Engine Guardian system may engage and protect the engine by limiting power. You should return to port immediately and contact your servicing dealer.

Intermittent short beeps for six seconds: Indicates a noncritical engine condition. This condition does not require immediate attention. You may continue using your boat, however, depending on the nature of the problem, the engine’s power may be limited by the Engine Guardian system to protect the engine. You should contact your servicing dealer at your earliest convenience.

It is important to note that in either of the above scenarios, the horn will only sound one time. If you key the engine off and restart it, the horn will sound again, one time, if the fault is still present.

A few of the noncritical conditions indicated by the intermittent short beeps for six seconds can be corrected by the operator. These operator correctable conditions are as follows:

•

Water in the fuel filter. Refer to Maintenance – Water Separating Fuel Filter.

• Cooling system (water pressure or engine temperature) problem. Stop the engine and check the water intake holes in the lower unit for obstruction.

•

Low engine oil level. Refer to Fuel and Oil – Checking and Adding Engine Oil.

Instrumentation

VesselView

Your power package may be connected to a SmartCraft VesselView display. VesselView 7 is a comprehensive boat information center that can display information for up to four gasoline or diesel engines. It continuously monitors and reports basic operating data including detailed information such as seawater temperature and depth, trim status, boat speed and steering angle, and the status of fuel, oil, water, and waste tanks.

VesselView can be fully integrated with a vessel’s global positioning system (GPS) or other NMEA‑compatible device to provide up‑to‑the‑minute navigation, speed, and fuel‑to‑destination information.

VesselView 4 and 7 are equipped with a micro SD card port that allows an authorized OEM or dealership to import the personality configuration. It can also be use by the owner to import pictures or graphics. When more than one VesselView is used, either as a triple or quad‑engine application for multiple helms, the same mico SD card can be used to download those configurations.

VesselView

Refer to your VesselView operations manual for detailed instructions on how to operate this display.

SmartCraft Speedometer, Tachometer, and Digital Gauges

The SmartCraft instrument package augments the information provided by VesselView. The instrument package may display:

• Engine RPM

• Boat speed

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• Coolant temperature

• Oil pressure

• Battery voltage

• Fuel consumption

• Engine operating hours

SmartCraft tachometer and speedometer

a - Tachometer b - Speedometer c - LCD display

The SmartCraft instrument package also aids in identifying the fault codes associated with the engine audio warning system. The SmartCraft instrument package displays critical engine alarm data and other potential problems on its LCD display.

For basic operation information on the SmartCraft instrument package and for details on the warning functions monitored by the system, refer to the manual provided with your gauge package.

System Link Digital Gauges

Some instrumentation packages include gauges that augment the information provided by VesselView and the SmartCraft tachometer and speedometer. The owner and operator should be familiar with all the instruments and their functions on the boat. Have your boat dealer explain the gauges and normal readings that appear on your boat.

The following types of digital gauges may be included with your power package.

System Link digital gauges

Item Gauge Indicates a Oil pressure gauge Engine oil pressure b Voltmeter Battery voltage c Water temperature gauge Engine operating temperature d Fuel gauge Quantity of fuel in tank

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Switches

Reference Switch Function

a Key switch Has four positions.

Bilge blower switch (if equipped) Operates the bilge blower, if equipped

a - Key switch b - Bilge blower switch (if equipped)

"OFF." In the "OFF" position, all electrical circuits are off and the engine cannot be started. The engine is stopped when the key switch is turned to the "OFF" position.

"ACC." In the "ACC" position, any accessory connections to the electrical circuits can be operated. The engine will not operate with the key switch in the "ACC" position.

"ON." In the "ON" position, all electrical circuits and instruments are operational.

"START." In the "START" position the engine can be started.

NOTE: The key can only be removed with the key switch in the "OFF" position.

Emergency Stop Switch

An emergency stop (E‑stop) switch is used to turn off the engines in an emergency situation, such as a person overboard or a tangled propeller. When activated, an E‑stop switch interrupts the power supply to the engine and transmission. If the boat is equipped with an E‑stop switch, the E‑stop switch turns off all of the engines.

Typical E-stop switch

Activation of an E‑stop switch stops the engine, or engines, immediately, but the boat can continue to coast for some distance depending upon the velocity and degree of any turn at shutdown. While the boat is coasting, it can cause injury to anyone in the boat's path as seriously as the boat would when under power.

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OFF

RUN

ATTACH LANYARD

We recommend instructing other occupants on proper starting and operating procedures should they need to operate the engine in an emergency.

Accidental or unintended activation of the switch during normal operation is also possible, which can cause any or all of the following potentially hazardous situations:

• Occupants can be thrown forward due to unexpected loss of forward motion, and passengers in the front of the boat could be ejected over the bow and possibly struck by the propulsion or steering components.

• The operator can lose power and directional control in heavy seas, strong current, or high winds.

• The operator can lose control of the vessel when docking.

Restarting an engine using the key switch or start button after an E‑stop shutdown without first turning the key switch to the off position for at least 30 seconds will restart the engine but cause fault codes to be set. Unless you are in a potentially hazardous situation, turn the key switch off and wait at least 30 seconds before restarting the engine or engines. If after restarting, some fault codes are still being displayed, contact your authorized Mercury Diesel repair facility.

Lanyard Stop Switch

A lanyard switch is designed to shut down the engine in the event the operator unexpectedly moves away from the helm, as may happen in an accidental ejection. The lanyard is connected to the operator's personal flotation device or wrist.

A decal near the lanyard stop switch reminds the operator to attach the lanyard to his or her personal flotation device or wrist.

a - Lanyard cord clip b - Lanyard decal c - Lanyard stop switch

Accidental ejections, such as falling overboard, are more likely to occur in:

• Low‑sided sport boats

• Bass boats

• High‑performance boats

Accidental ejections can also occur from:

• Poor operating practices

• Sitting on the seat or gunwale at planing speeds

• Standing at planing speeds

• Operating at planing speeds in shallow or obstacle‑infested waters

• Releasing your grip on the steering wheel

• Carelessness caused by consuming alcohol or drugs

• High‑speed boating maneuvers

The lanyard is a cord usually between 122 and 152 cm (4 and 5 ft) long when stretched out, with an element on one end made to be inserted into the switch, and a snap on the other end for attaching to the operator. The lanyard is coiled to make its at‑rest condition as short as possible to minimize the likelihood of lanyard entanglement with nearby objects. Its stretched‑out length is made to minimize the likelihood of accidental activation should the operator choose to move around in an area close to the operator's normal position. The operator can shorten the lanyard by wrapping the lanyard around his wrist, or by tying a knot in the lanyard.

Activation of the lanyard stop switch will stop the engine immediately, but the boat will continue to coast for some distance, depending upon its velocity. While the boat is coasting, it can cause injury to anyone in the boat's path as it would under power.

Instruct all passengers on the proper starting and operating procedures should they be required to operate the boat in an emergency.

If the operator falls out of the boat, stop the engine immediately to reduce the possibility of serious injury or death from being struck by the boat. Always properly connect the operator to the stop switch using a lanyard.

WARNING

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Accidental or unintended activation of the switch during normal operation is also a possibility. This could cause any, or all, of the following potentially hazardous situations:

• Occupants could be thrown forward due to unexpected loss of forward motion, a particular concern for passengers in the front of the boat who could be ejected over the bow and possibly struck by the propulsion or steering components.

• Loss of power and directional control in heavy seas, strong current, or high winds.

• Loss of control when docking.

WARNING

Avoid serious injury or death from deceleration forces resulting from accidental or unintended stop switch activation. The boat operator should never leave the operator's station without first disconnecting the stop switch lanyard from the operator.

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Before each use, ensure that the lanyard stop switch works properly. Start the engine, and then stop it by pulling the lanyard cord. If the engine does not stop, have the switch repaired before operating the boat.

Before each use, inspect the lanyard cord to ensure that it is in good working condition and that there are no breaks, cuts, or wear to the cord. Check that the clips on the ends of the cord are in good condition. Replace any damaged or worn lanyard cords.

Digital Throttle and Shift

Digital Throttle and Shift (DTS) operating instructions are provided in a separate manual. Refer to Mercury Diesel's SmartCraft and DTS Operator's Manual.

Remote Controls

Your boat may be equipped with Mercury Precision Parts or Quicksilver remote controls. All controls may not have all features shown. Consult your dealer for a description or demonstration of your remote control.

Panel Mount Features

Neutral lock button. Prevents accidental shift and throttle engagement. The neutral lock button must be pushed in to move the control handle out of neutral.

Throttle‑only button. Allows engine throttle advancement without shifting the engine. This is done by disengaging the shift mechanism from the control handle. The throttle‑only button can be pressed only when the remote control handle is in the neutral position, and should only be used to assist in starting the engine.

Lanyard stop switch. Turns the ignition off whenever the operator (when attached to the lanyard) moves far enough away from the operator's position to activate the switch. Refer to Lanyard Stop Switch for information on the use of this switch.

Control handle. Operation of the shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear. Continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Control handle tension adjustment screw (not visible). This screw is used to adjust the effort required to move the remote control handle. Refer to the instructions provided with the remote control for complete adjustment instructions.

a - Neutral lock button b - Throttle‑only button c - Lanyard stop switch d - Control handle tension adjustment screw e - Control handle

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Console Mount Features

a - Control handle b - Throttle‑only button

Control handles. Operation of the shift and throttle is controlled by the movement of the control handle. Push the control handle forward from neutral with a quick, firm motion to the first detent for forward gear and continue pushing forward to increase speed. Pull the control handle back from neutral with a quick, firm motion to the first detent for reverse gear and continue pushing back to increase speed.

Engine Electrical System Overload Protection

If an electrical overload occurs, a fuse will open (blow). Find and correct the cause of the electrical overload before replacing the fuse.

NOTE: In an emergency, when the engine must be operated and the cause of the electrical overload cannot be located and corrected, turn off or disconnect all the accessories connected to the engine and instrumentation wiring. Replace the blown fuse. If the replacement fuse also blows, then the electrical overload has not been eliminated. Further checks must be made on the electrical system.

higher amperage fuse or shorting across the fuse block terminals.

Fuses provide protection for the engine electrical system as indicated. The fuse panel is located beneath an access panel in the front of the engine cover.

Do not circumvent the electrical overload protection provided on fused circuits by installing a

Contact your Mercury Diesel authorized repair facility.

2.0 engine cover with access panel

a - Engine cover access panel b - Fuse panel

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After finding and correcting the cause of the overload, replace any open (blown) fuses.

2.0 fuse panel

Reference Fuse Protection

a 20‑amp Unswitched power to helm Lower left b 10‑amp Switched power to ECM Middle left c 10‑amp Keyed power to ECM Upper left d 5‑amp Power—diagnostic connector Upper right e 15‑amp ECM switched power to SIM Middle right

f 15‑amp Switched power to ECM Lower right

Location on fuse panel (From Front of Engine)

Vessel Integration Panel (VIP) Overload Protection

A vessel integration panel (VIP) is typically mounted in the engine compartment. The VIP contains three circuit breakers that help protect system wiring.

a - Helm circuit breaker (10 A) b - Gear circuit breaker (15 A) c - SIM/Vessel circuit breaker (10 A)

Engine Guardian System

The Engine Guardian system monitors the critical sensors on the engine for any early indications of problems. Engine Guardian is functional whenever your engine is operating, so you never have to be concerned about whether or not you are protected. The system will respond to a problem by sounding the warning horn for six seconds and/or reducing engine power in order to provide engine protection.

If Engine Guardian has been activated, reduce the engine speed. The problem will need to be identified and corrected. The system must be reset before the engine will operate at higher speeds. Moving the throttle lever back to the idle position will reset the Engine Guardian system. If the Engine Guardian system has determined the reset has not corrected the problem, Engine Guardian will remain activated, limiting the throttle. The problem must be identified and corrected before Engine Guardian will allow the engine to reach a normal operating RPM.

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Identification

The serial numbers are the manufacturer's keys to numerous engineering details that apply to your Mercury Marine power package. When contacting Mercury Marine about service, always specify model and serial numbers.

Specifications Label

A specifications label on the top of the engine cover provides quick reference information for the engine and drive with color codes that identify where to check specific types of fluids and the belt routing. A QR code can be scanned with a smartphone for more engine information.

Data Label Location

The engine data label is located on the front of the engine as shown below.

a - Serial number and part

number label, with bar codes

b - Engine data label

Engine Data Label

A tamper‑resistant engine data label is affixed to the engine at the time of manufacture. It contains important information. Note that the engine data label will not affect the fit, function, or performance of the engine and neither boatbuilders nor dealers may remove the engine data label or the engine component it is affixed to before sale. If modifications are necessary or the engine data label is damaged, contact Mercury Marine about the availability of a replacement.

The owner or operator is not to modify the engine in any manner that would alter the horsepower or allow exhaust gas emission levels to exceed their predetermined factory specifications.

Engine data label example

a - Engine weight b - Engine power rating c - Maximum engine speed (RPM) d - Engine serial number e - Abbreviated engine description

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Technodrive Transmissions

The transmission identification plate indicates gear ratio, serial number, and model.

Technodrive TM 345 identification plate

Technodrive TM 485-A identification plate

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Table of Contents

Section 2 - On the Water

Safe Boating Recommendations.......................................... 12

Carbon Monoxide Exposure................................................. 13

Be Alert To Carbon Monoxide Poisoning ..................... 13

Stay Clear of Exhaust Areas ........................................ 13

Good Ventilation .......................................................... 13

Poor Ventilation ........................................................... 14

Important Operation Information........................................... 14

Launching...................................................................... 14

Duty Cycle Rating Requirements...................................14

High‑Output Rating........................................................ 14

Operation Chart............................................................. 15

Freezing Temperature and Cold Weather Operation.... 15

Drain Plug and Bilge Pump............................................16

Starting, Shifting, and Stopping............................................ 16

Before Starting the Engine.............................................16

Important Information—SmartStart................................ 16

Starting a Cold Engine................................................... 16

Engine Warm Up........................................................... 17

Starting a Warm Engine ................................................17

Shifting........................................................................... 17

Engine Shut Down (Stopping)....................................... 17

Protecting People in the Water............................................. 18

While Boat is in Operation ............................................ 18

While the Boat is Stationary ......................................... 18

High‑Speed and High‑Performance..................................... 18

Passenger Safety In Pontoon Boats and Deck Boats.......... 18

Boats Having An Open Front Deck .............................. 18

Boats With Front‑Mounted, Raised Pedestal Fishing

Seats ............................................................................ 19

Wave and Wake Jumping..................................................... 19

Impact With Underwater Hazards......................................... 19

Conditions Affecting Operation............................................. 20

Weight Distribution (Passengers and Gear) Inside the

Boat............................................................................... 20

Bottom of Boat............................................................... 20

Elevation and Climate.................................................... 20

Propeller Selection.........................................................21

Getting Started..................................................................... 21

Initial Break‑In Procedure.............................................. 21

Engine Break‑In............................................................. 21

20‑Hour Break‑In Period ....................................... 21

After the 20‑Hour Break‑In Period ......................... 21

End of First Season Checkup........................................ 22

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Section 2 - On the Water

Safe Boating Recommendations

To safely enjoy the waterways, familiarize yourself with local and all other governmental boating regulations and restrictions and consider the following suggestions.

Know and obey all nautical rules and laws of the waterways.

• We recommend that all powerboat operators complete a boating safety course. In the U.S., the U.S. Coast Guard Auxiliary, the Power Squadron, the Red Cross, and your state or provincial boating law enforcement agency provide courses. For more information in the U.S., call the Boat U.S. Foundation at 1‑800‑336‑BOAT (2628).

Perform safety checks and required maintenance.

• Follow a regular schedule and ensure that all repairs are properly made.

Check safety equipment onboard.

• Here are some suggestions of the types of safety equipment to carry when boating:

Approved fire extinguishers

Signal devices: flashlight, rockets or flares, flag, and whistle or horn

Tools necessary for minor repairs

Anchor and extra anchor line

Manual bilge pump and extra drain plugs

Drinking water

Radio

Paddle or oar

Spare propeller, thrust hubs, and an appropriate wrench

First aid kit and instructions

Waterproof storage containers

Spare operating equipment, batteries, bulbs, and fuses

Compass and map or chart of the area

Personal flotation device (one per person onboard)

Watch for signs of weather change and avoid foul weather and rough‑sea boating.

Tell someone where you are going and when you expect to return.

Passenger boarding.

• Stop the engine whenever passengers are boarding, unloading, or are near the back (stern) of the boat. Shifting the drive unit into neutral is not sufficient.

Use personal flotation devices.

• Federal law requires that there be a U.S. Coast Guard‑approved life jacket (personal flotation device), correctly sized and readily accessible for every person onboard, plus a throwable cushion or ring. We strongly advise that everyone wear a life jacket at all times while in the boat.

Prepare other boat operators.

• Instruct at least one person onboard in the basics of starting and operating the engine and boat handling in case the driver becomes disabled or falls overboard.

Do not overload your boat.

• Most boats are rated and certified for maximum load (weight) capacities (refer to your boat's capacity plate). Know your boat's operating and loading limitations. Know if your boat will float if it is full of water. When in doubt, contact your authorized Mercury Marine dealer or the boat manufacturer.

Ensure that everyone in the boat is properly seated.

• Do not allow anyone to sit or ride on any part of the boat that was not intended for such use. This includes the backs of seats, gunwales, transom, bow, decks, raised fishing seats, and any rotating fishing seat. Passengers should not sit or ride anywhere that sudden unexpected acceleration, sudden stopping, unexpected loss of boat control, or sudden boat movement could cause a person to be thrown overboard or into the boat. Ensure that all passengers have a proper seat and are in it before any boat movement.

Never operate a boat while under the influence of alcohol or drugs. It is the law.

• Alcohol or drugs can impair your judgment and greatly reduce your ability to react quickly.

Know your boating area and avoid hazardous locations.

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Be alert.

• The operator of the boat is responsible by law to maintain a proper lookout by sight and hearing. The operator must have

an unobstructed view particularly to the front. No passengers, load, or fishing seats should block the operator's view when the boat is above idle or planing transition speed. Watch out for others, the water, and your wake.

Never drive your boat directly behind a water skier.

• Your boat traveling at 40 km/h (25 mph) will overtake a fallen skier who is 61 m (200 ft) in front of you in five seconds.

Watch fallen skiers.

• When using your boat for waterskiing or similar activities, always keep a fallen or down skier on the operator's side of the

boat while returning to attend to the skier. The operator should always have the down skier in sight and never back up to the skier or anyone in the water.

Report accidents.

• Boat operators are required by law to file a boating accident report with their state boating law enforcement agency when

their boat is involved in certain boating accidents. A boating accident must be reported if 1) there is loss of life or probable loss of life, 2) there is personal injury requiring medical treatment beyond first aid, 3) there is damage to boats or other property where the damage value exceeds $500.00, or 4) there is complete loss of the boat. Seek further assistance from local law enforcement.

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Carbon monoxide (CO) is a deadly gas that is present in the exhaust fumes of all internal combustion engines, including the engines that propel boats, and the generators that power boat accessories. By itself, CO is odorless, colorless, and tasteless, but if you can smell or taste engine exhaust, you are inhaling CO.

Early symptoms of carbon monoxide poisoning, which are similar to the symptoms of seasickness and intoxication, include headache, dizziness, drowsiness, and nausea.

WARNING

Inhaling engine exhaust gases can result in carbon monoxide poisoning, which can lead to unconsciousness, brain damage, or death. Avoid exposure to carbon monoxide.

Stay clear from exhaust areas when engine is running. Keep the boat well‑ventilated while at rest or underway.

Stay Clear of Exhaust Areas

Engine exhaust gases contain harmful carbon monoxide. Avoid areas of concentrated engine exhaust gases. When engines are running, keep swimmers away from the boat, and do not sit, lie, or stand on swim platforms or boarding ladders. While underway, do not allow passengers to be positioned immediately behind the boat (platform dragging, teak/body surfing). This dangerous practice not only places a person in an area of high engine exhaust concentration, but also subjects them to the possibility of injury from the boat propeller.

Good Ventilation

Ventilate the passenger area, open side curtains or forward hatches to remove fumes. Example of desired air flow through the boat:

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Poor Ventilation

Under certain running or wind conditions, permanently enclosed or canvas enclosed cabins or cockpits with insufficient ventilation may draw in carbon monoxide. Install one or more carbon monoxide detectors in your boat.

Although the occurrence is rare, on a very calm day, swimmers and passengers in an open area of a stationary boat that contains or is near a running engine may be exposed to a hazardous level of carbon monoxide.

1. Examples of poor ventilation while the boat is stationary:

a - Operating the engine when the boat

is moored in a confined space

b - Mooring close to another boat that

has its engine operating

2. Examples of poor ventilation while the boat is moving:

a - Operating the boat with the

trim angle of the bow too high

b - Operating the boat with no

forward hatches open (station wagon effect)

Important Operation Information

Launching

IMPORTANT: Install the bilge drain plug before launching the boat.

Duty Cycle Rating Requirements

IMPORTANT: Damage caused by incorrect application or failure to operate the power package within the specified operating parameters will not be covered by the Mercury Marine Limited Warranty.

Mercury Diesel engines must be used in applications that meet the operation specifications indicated by a Mercury Diesel product application engineer. The power package must be equipped with a gear ratio and propeller that allows the engine to operate at wide open throttle (WOT) at the engine's rated speed (RPM). Use of Mercury Diesel engines in applications that do not meet specified operational parameters is not approved.

High‑Output Rating

A High‑output rating applies to pleasure (nonrevenue generating) applications that operate 500 hours or less per year, where full power is limited to one (1) hour out of every eight (8) hours of operation. Reduced power operation must be at or below cruise speed (RPM). Cruise speed is dependant on the engine's maximum rated speed (RPM).

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Operation Chart

Starting Procedure After Starting While Underway Stopping and Shut Down

Open the engine hatch. Air out the bilge completely.

Turn the battery switch on, if equipped.

Turn on and run the engine compartment bilge blower, if equipped, for five minutes.

Check for leaks: fuel, oil, water, fluid, etc.

Open the fuel shut‑off valve, if equipped.

Open the seacock, if equipped.

Prime the fuel injection system, if necessary.

Turn the key switch to "START" position. Release the key when the engine starts.

Warm‑up the engine at a fast idle‑RPM for several minutes.

Observe all instrumentation to monitor the condition of the engine. If not normal, stop the engine.

Check for fuel, oil, water, fluid, and exhaust leaks, etc.

Check shift and throttle control operation.

Check steering operation.

Frequently review all instrumentation to monitor engine condition.

Listen for the audio alarm.

Shift the remote control lever to the neutral position.

Run the engine at idle‑RPM for several minutes to allow the turbocharger and engine to cool.

Turn the key switch to "OFF" position.

Turn the battery switch off, if equipped.

Close the fuel shut‑off valve, if equipped.

Close the seacock, if equipped.

Flush the seawater cooling circuit, if operating in saltwater, brackish water, or polluted water.

Freezing Temperature and Cold Weather Operation

IMPORTANT: If the boat is operated during periods of freezing temperature, take precautions to prevent freezing damage to the power package. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

NOTICE

Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures. If the boat is in the water, keep the seacock closed until restarting the engine to prevent water from flowing back into the cooling system. If the boat is not fitted with a seacock, leave the water inlet hose disconnected and plugged.

NOTE:

As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open

the seacock or unplug and connect the water inlet hose before starting the engine.

In order to operate the engine in temperatures of 0° C (32° F) or lower, observe the following instructions:

• At the end of each daily operation, completely drain the seawater section of the cooling system to protect against damage

by freezing.

• At the end of each daily operation, drain the water from the water separator, if equipped. Fill the fuel tank at the end of daily

operation to prevent condensation.

• Use the required permanent‑type antifreeze solution to protect components against damage by freezing.

• Use proper cold weather lubrication oil; ensure that the crankcase contains a sufficient amount.

• Make certain that the battery is of sufficient size and is fully charged. Check that all other electrical equipment is in

optimum condition.

• At temperatures of –20° C (–4° F) and below, use a coolant heater to improve cold starting.

• If operating in arctic temperatures of –29° C (–20° F) or lower, consult your Mercury Diesel authorized repair facility for

information about special cold weather equipment and precautions.

Refer to Section 6 for cold weather or extended storage related information.

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Drain Plug and Bilge Pump

The engine compartment in your boat is a natural place for water to collect. For this reason, boats are normally equipped with a drain plug or a bilge pump. It is important to check these items on a regular basis to ensure that the water level does not come into contact with your power package. Components on your engine will be damaged if submerged. Damage caused by submersion is not covered by the Mercury Marine Limited Warranty.

Starting, Shifting, and Stopping

WARNING

Vapors can ignite and cause an explosion, resulting in engine damage or severe personal injury. Do not use volatile starting aids such as ether, propane, or gasoline in the engine air intake system.

WARNING

Fuel vapors trapped in the engine compartment may be an irritant, cause difficulty breathing, or may ignite resulting in a fire or explosion. Always ventilate the engine compartment before servicing the power package.

Before Starting the Engine

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

IMPORTANT: Observe the following before starting the engine:

• Provide water to the seawater pickup pump.

• Ensure that the engine crankcase is filled to the correct level with the proper grade of oil for the prevailing temperature. Refer to Section 4 ‑ Specifications.

• Ensure that all electrical connections are secure.

• Check all applicable items in the maintenance schedules and operation chart.

• Perform any other necessary checks as indicated by your Mercury Diesel authorized repair facility or specified in your boat owner's and operation manual.

Important Information—SmartStart

IMPORTANT: This Mercury Diesel model is equipped with SmartStart. SmartStart performs all appropriate starting operations upon initial start switch activation. To begin the SmartStart sequence, turn the ignition key switch to the "START" position and release, or turn the ignition key switch to the run position and press and release the start/stop switch.

Rather than holding the start button or key switch in position until the engine starts, SmartStart controls the starting process automatically. When the start switch is activated, the system signals the engine ECM to start the engine. The starter will receive power until the engine starts, the starting process times out after a few seconds, or when the engine reaches 400 RPM. Attempting to start the engine with the engine running will turn the engine off.

Starting a Cold Engine

WARNING

A spinning propeller, a moving boat, or any solid device attached to the boat can cause serious injury or death to swimmers. Stop the engine immediately whenever anyone in the water is near your boat.

NOTE: Check the fluid levels before starting the engine. Refer to

1. Turn on and run the engine compartment bilge blower (if equipped) for five minutes. Alternately, open the engine hatch to air out the bilge before attempting to start the engine.

2. Place the control handle in neutral.

NOTE: If the engine has not been run for a period of time and will not readily start with the standard starting procedure, use the fuel primer located on the fuel filter header. Cycle the primer plunger up and down four or five strokes before attempting to start the engine.

3. Turn the ignition key to the "RUN" position.

4. Turn the ignition key switch to the "START" position then release, or press the start/stop button and release. If the engine is cold, allow the engine to operate at idle for 6–10 minutes or until the engine reaches normal operating temperature. IMPORTANT: Engine oil pressure should exceed 69 kPa (10 psi) within seconds of starting the engine. Stop the engine if the engine oil pressure does not meet this specification. Locate and correct the problem. If you are unable to correct the problem, see a Mercury Diesel authorized repair facility.

Section 5 ‑ Maintenance Schedule

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5. Verify that all instrumentation is functioning properly and indicating normal readings.

Engine Warm Up

NOTICE

Engine wear caused by increased friction and limited oil flow is greatest when an engine is cold. Decrease engine wear by allowing the engine coolant temperature to reach normal operating range before hard acceleration or applying full throttle.

1. After starting, ensure that all instrumentation is functioning properly.

2. Operate the engine at 1,000 to 1,200 RPM until the engine temperature is within the normal operating range. It is crucial

that any engine be warmed up before applying full load. The warm‑up period provides time for the lubricating oil to establish a film between moving parts.

NOTE: Engine warm‑up time during cold weather can be reduced by operating the vessel at a reduced engine speed. Begin normal vessel operation when systems reach operating temperatures.

3. After the engine has reached operating temperature:

The oil pressure should be within the range specified. Refer to Section 4 ‑ Engine Specifications. Stop the engine if

the oil pressure is not within the range specified. b. Check the fuel system for leakage from the injection pump, fuel pipes, fuel filter, or fuel lines. c. Check the engine and the transmission, oil filter, oil lines, oil line connectors, and oil pan for leaks. d. Check the coolant hoses, heat exchanger connections, aftercooler, water pump, and drain fittings for leaks.

4. Locate and correct any problems, or see your Mercury Diesel authorized repair facility if you are unable to determine the problem.

Starting a Warm Engine

1. Turn on and run the engine compartment bilge blower (if equipped) for 5 minutes. Or, open the engine hatch to air out the bilge before attempting to start the engine.

2. Place the remote control handle in neutral.

3. Turn the key switch to "START" position and release the key when the engine starts.

4. Ensure that all the instrumentation is functioning properly and indicates normal readings.

Shifting

NOTICE

Shifting into gear at engine speeds above idle will damage the transmission. Shift into gear only when the engine is operating at idle.

NOTICE

Failure to rotate the propeller shaft when shifting gears or forcing the shift mechanism while the engine is not operating can result in product damage. If you must shift gears with the engine off, manually rotate the propeller shaft in the appropriate direction.

To shift the unit, verify the remote control throttle lever is in neutral. Move the remote control shift lever forward to shift into forward gear or backward to shift into reverse. After shifting the transmission, advance the throttle to the desired setting.

Engine Shut Down (Stopping)

1. Place the remote control lever in neutral.

NOTICE

Immediately stopping the engine after high load operation can damage the turbocharger bearings. Idle the engine for several minutes before shutdown.

2. Operate the engine at idle speed for several minutes to allow the turbocharger and engine to cool.

3. The engine can be stopped by any one of the following four methods:

a. Move the ignition key switch to the "ACCESSORY" or "OFF" position. The engine will stop and the control system will

be deactivated.

b. Depress the start/stop button, if equipped. The engine will stop and the control system will remain active.

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c. Momentarily move the ignition key switch to the "START" position, then release immediately. The control system will

recognize that the engine is running and will stop the engine. The control system will remain active. Moving the ignition key switch to the "START" position again will issue a start request to the control system and the control system will start the engine, if appropriate.

d. Activate the lanyard stop switch, if equipped. The engine will stop, but the control system will remain active. The

control system will not allow the engine to start if the lanyard stop switch is activated.

Protecting People in the Water

While Boat is in Operation

People in the water cannot take quick action to avoid a boat heading in their direction.

Approach slowly and exercise extreme caution when boating in areas where people may be in the water. When a boat is moving and the gear shift is in neutral, there is sufficient force by the water on the propeller to cause the

propeller to rotate. This neutral propeller rotation can cause serious injury.

While the Boat is Stationary

WARNING

Shift into neutral and shut down the engine before allowing people in the water near the boat.

High‑Speed and High‑Performance

If your boat is considered a high‑speed or high‑performance boat, we recommend that you never operate it at its high‑speed capability without first requesting an initial orientation and demonstration ride with your dealer or an operator experienced with your boat. For additional information, refer to the Hi‑Performance Boat Operation booklet from your Mercury Diesel authorized repair facility.

Passenger Safety In Pontoon Boats and Deck Boats

Whenever the boat is in motion, observe the location of all passengers. Do not allow any passengers to stand or use seats other than those designated for traveling faster than idle speed. A sudden reduction in boat speed, such as plunging into a large wave or wake, a sudden throttle reduction, or a sharp change of boat direction, could throw them over the front of boat. Falling over the front of the boat between the two pontoons will position them to be run over.

Boats Having An Open Front Deck

No one should ever be on the deck in front of the rail while the boat is in motion. Keep all passengers behind the front rail or enclosure.

Persons on the front deck could easily be thrown overboard or persons dangling their feet over the front edge could get their legs caught by a wave and pulled into the water.

mc79555-1

WARNING

Sitting or standing in an area of the boat not designed for passengers at speeds above idle can cause serious injury or death. Stay back from the front end of deck boats or raised platforms and remain seated while the boat is in motion.

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Boats With Front‑Mounted, Raised Pedestal Fishing Seats

Elevated fishing seats are not intended for use when the boat is traveling faster than idle or trolling speed. Sit only in seats designated for traveling at faster speeds.

Any unexpected, sudden reduction in boat speed could result in the elevated passenger falling over the front of the boat.

mc79557-1

Wave and Wake Jumping

WARNING

Wave or wake jumping can cause serious injury or death from occupants being thrown within or out of the boat. Avoid wave or wake jumping whenever possible.

mc79680-1

Operating recreational boats over waves and wakes is a natural part of boating. However, when this activity is done with enough speed to force the boat hull partially or completely out of the water, certain hazards arise, particularly when the boat reenters the water.

The primary concern is the boat changing direction while in the midst of the jump. In such cases the landing may cause the boat to violently veer in a new direction. Such a sharp change in direction or turn can cause occupants to be thrown out of their seats or out of the boat.

There is another less common hazardous result from allowing your boat to launch off of a wave or wake. If the bow of your boat pitches down far enough while airborne, upon water contact it may penetrate under the water surface and submarine for an instant. This will bring the boat nearly to a stop in an instant and can send the occupants flying forward. The boat may also veer sharply to one side.

Impact With Underwater Hazards

17269

Reduce speed and proceed with caution whenever you're driving a boat in shallow water areas or in areas where the waters are suspected of having underwater obstacles that could be struck by the underwater drive components, rudder, or the boat bottom. The most important thing you can do to help reduce injury or impact damage from striking a floating or underwater object is control the boat speed. Under these conditions, boat speed should be kept to a minimum planing speed of 24 to 40 km/h (15 to 25 MPH).

Striking a floating or underwater object may result in an infinite number of situations. Some of these situations could result in the following:

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• The boat could move suddenly in a new direction. Such a sharp change in direction or turn can throw occupants out of their seats or out of the boat.

• A rapid reduction in speed. This will throw occupants forward, even out of the boat.

• Impact damage to the underwater drive components, rudder, or boat.

Keep in mind, one of the most important things you can do to help reduce injury or impact damage in these situations is control the boat speed. Boat speed should be kept to a minimum planing speed when driving in waters known to have underwater obstacles.

After striking a submerged object, stop the engine as soon as possible and inspect the drive system for any broken or loose parts. If damage is present or suspected, take the power package to an authorized dealer for a thorough inspection and necessary repair.

The boat should also be checked for any hull fractures, transom fractures, and water leaks. Operating with damaged underwater drive components, rudder, or boat bottom could cause additional damage to other parts of

the power package, or could affect control of the boat. If continued running is necessary, do so at greatly reduced speeds.

WARNING

Operating a boat or engine with impact damage can result in product damage, serious injury, or death. If the vessel experiences any form of impact, have an authorized Mercury Marine dealer inspect and repair the vessel or power package.

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Shifting weight to rear (stern):

• Generally increases speed and engine RPM

• Causes bow to bounce in choppy water

• Increases danger of following wave splashing into the boat when coming off plane

• At extremes, can cause the boat to porpoise

Shifting weight to front (bow):

• Improves ease of planing

• Improves rough water ride

• At extremes, can cause the boat to veer back and forth (bow steer)

Bottom of Boat

To maintain maximum speed, ensure that the boat bottom is:

• Clean, free of barnacles and marine growth.

• Free of distortion, nearly flat where it contacts water.

• Straight and smooth, fore and aft.

Marine vegetation may accumulate when the boat is docked. This growth must be removed before operation; it may clog water inlets and cause the engine to overheat.

Elevation and Climate

NOTE: Engines equipped with an Engine Control Module (ECM) reduce the effects of changes in elevation and climate by automatically adjusting fuel flow for weather conditions and elevation. ECM controlled engines, however, do not compensate for increased loading or hull conditions.

Elevation and climate changes affect the performance of your power package. Loss of performance can be caused by:

• High elevations

• High temperatures

• Low barometric pressures

• High humidity

For optimum engine performance under changing weather conditions and high elevation, use a propeller that allows the engine to operate at rated RPM at wide open throttle (WOT) with a maximum boat load during your normal boating.

In most cases, the rated RPM at WOT can be achieved by changing to a lower pitch propeller.

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Propeller Selection

NOTICE

Operating the engine with the wrong propeller installed can limit power, increase fuel consumption, overheat the engine, or cause internal powerhead damage. Choose a propeller that allows the engine to operate at the specified wide open throttle RPM.

The boat manufacturer and the selling dealer are responsible for equipping the power package with the correct propellers. IMPORTANT: The engines covered in this manual are equipped with an ECM that limits engine RPM. Be sure that the propeller

being used does not allow the engine to run against the limiter, as a significant loss in performance will result.

NOTE: Use an accurate service tachometer to verify RPM.

Select a propeller that will allow the engine power package to operate at the rated engine RPM with a maximum load. If full throttle operation is below the engine rated RPM, the propeller must be changed to prevent loss of performance and

possible engine damage. On the other hand, operating an engine above the rated engine RPM will cause higher than normal wear or damage.

After initial propeller selection, the following common problems may require that the propeller be changed to a lower pitch:

• Warmer weather and greater humidity cause an RPM loss (not as significant on these models).

• Operating in a higher elevation causes an RPM loss (not as significant on these models).

• Operating with a damaged propeller or dirty boat bottom causes an RPM loss.

• Operating with increased load (additional passengers, pulling skiers). For better acceleration, such as is needed for water skiing, use the next lower pitch propeller. Do not operate at full throttle

when using the lower pitch propeller but not pulling skiers.

Getting Started

Initial Break‑In Procedure

It is important to follow this procedure to properly break in the engine. IMPORTANT: Mercury Marine recommends that the boat not be accelerated hard until this procedure has been completed.

IMPORTANT: Never operate the starter motor longer than 15 seconds at a time to avoid overheating the starter motor. If the engine does not start, wait one minute to allow the starter motor to cool; then, repeat the starting procedure.

Refer to the appropriate Starting, Shifting, and Stopping section and start the engine.

2. Operate the engine at a fast idle until it has reached normal operating temperature.

3. Operate the engine in gear for three minutes at each of the following: 1200 RPM, 2400 RPM, and 3000 RPM.

4. Operate the engine in gear for three minutes at each of the following: 1500 RPM, 2800 RPM, and 3400 RPM.

5. Operate the engine in gear for three minutes at each of the following: 1800 RPM, 3000 RPM, and maximum rated full

throttle RPM.

Engine Break‑In

20-Hour Break-In Period

IMPORTANT: The first 20 hours of operation are considered to be the engine break‑in period. Correct break‑in is essential to obtain minimum oil consumption and maximum engine performance. During this break‑in period, observe the following rules:

• Do not operate below 1500 RPM for extended periods of time for the first 10 hours. Shift into gear as soon as possible after

starting, and advance the throttle above 1500 RPM if conditions permit safe operation.

• Do not operate at one constant speed for extended periods.

• Do not exceed 3/4 throttle during the first 10 hours. During the next 10 hours, occasional operation at full throttle is

permissible (five minutes at a time maximum).

• Avoid full‑throttle acceleration from idle speed.

• Do not operate at full throttle until the engine reaches normal operating temperature.

• Check the engine oil level frequently. Add oil as needed. High oil consumption is normal during the break‑in period.

After the 20-Hour Break-In Period

To help extend the life of your power package, Mercury Marine recommends the following:

•

Change the engine oil and filter and the transmission fluid at the interval indicated in the Maintenance Schedule. Refer to Specifications and Maintenance.

• Use a propeller that allows the engine to operate at the rated engine RPM when at full throttle with a fully loaded boat.

Refer to Specifications and Maintenance.

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• Operation at 3/4 throttle setting or lower is recommended. Refrain from prolonged operation at wide‑open throttle RPM.

End of First Season Checkup

At the end of the first season of operation, contact an authorized repair facility to discuss or perform scheduled maintenance items. If you are in an area where the product is operated continuously, year‑round, you should contact your dealer at the end of the first 100 hours of operation or once yearly, whichever occurs first.

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Table of Contents

Section 3 - Specifications

Fuel Requirements............................................................... 24

Diesel Fuel in Cold Weather................................................. 24

Antifreeze/Coolant................................................................ 24

Engine Oil............................................................................. 25

Engine Specifications ‑ Inboard Models............................... 25

Fluid Specifications............................................................... 26

Engine............................................................................26

Transmission................................................................. 26

Approved Paints................................................................... 26

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Section 3 - Specifications

Fuel Requirements

WARNING

Failure to comply with regulations can result in injury from fire or explosion. Electrical system components on this engine are not rated as external ignition–protected (EIP). Do not store or use gasoline on boats equipped with these engines, unless provisions have been made to exclude gasoline vapors from the engine compartment (REF: 33 CFR).

WARNING

Fuel leakage is a fire or explosion hazard, which can cause serious injury or death. Periodically inspect all fuel system components for leaks, softening, hardening, swelling, or corrosion, particularly after storage. Any sign of leakage or deterioration requires replacement before further engine operation.

WARNING

This engine requires diesel fuel. Mixing gasoline, gasohol, or alcohol and diesel fuel can cause serious injury or death due to fire or explosion. Never mix gasoline, gasohol, or alcohol with diesel fuel.

IMPORTANT: Use of improper or water‑contaminated diesel fuel can seriously damage your engine. Use of improper fuel is considered misuse of the engine, and damage caused thereby will not be covered by the warranty.

Mercury diesels are required to use grade 2–D ULSD (ultra‑low sulphur diesel) fuel meeting ASTM Standards D975 (or fuel rated Diesel DIN EN 590), and having a minimum cetane rating of 51.

BIODIESEL: The blend of diesel fuel used may not contain more than 7% biodiesel fuel. Use of LSD or blends of ULSD fuel containing more than 7% biodiesel fuel may result in fuel system degradation, injection nozzle clogging, hard starting, increased oil change intervals, or excessive exhaust smoke.

The cetane number is a measure of the ignition quality of diesel fuel. Increasing the cetane number will not improve overall engine performance, but it may be necessary to raise the cetane rating for low‑temperature or high‑altitude use. A lower cetane number could cause hard starting and slower warm‑up, and could increase engine noise and exhaust emissions.

NOTE: If your engine suddenly becomes noisy after a fill‑up, you possibly received substandard fuel with a low cetane rating.

On engines that use high sulphur content diesel fuel, this will greatly increase:

• Corrosion on metal parts

• Deterioration of elastomer and plastic parts

• Excessive wear of internal engine parts, particularly bearings, and corrosion and extensive damage to other engine parts

• Difficulty starting and operating the engine

Diesel Fuel in Cold Weather

Unaltered diesel fuels thicken and gel in cold temperatures unless treated. Virtually all diesel fuels are climatized to allow their use in the particular region for that time of the year. If it becomes necessary to further treat diesel fuel, it is the owner/operator's responsibility to add a commercial standard brand of antigel diesel fuel additive, following that product's directions.

Antifreeze/Coolant

NOTICE

Using propylene glycol antifreeze in the closed cooling system can damage the cooling system or the engine. Fill the closed cooling system with an ethylene glycol antifreeze solution suitable to the lowest temperature to which the engine will be exposed.

Diesel engines are high‑compression engines that operate at higher temperatures than typical internal combustion engines. Therefore, the closed‑cooling system and engine, including related cooling passages, must remain as clean as possible to provide adequate engine cooling. To ensure proper cooling, we recommend filling the closed‑cooling section of the cooling system with a low silicate formula of ethylene glycol antifreeze in a solution with deionized water. Common tap water or softened water contains unwanted minerals that can leave large deposits in the system that restrict the cooling system efficiency. A low silicate formula prevents the antifreeze from separating and forming a silicate gelatin. This gelatin can block passages in the engine and heat exchanger, causing the engine to overheat.

Only premixed coolant should be added to the closed‑cooling system. Additives and inhibitors introduced into acceptable coolant solutions will form a protective film on the internal passages and provide protection against internal cooling system erosion.

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Section 3 - Specifications

Do not drain the closed‑cooling section for storage. The closed‑cooling section should be kept filled year‑round with an acceptable antifreeze/coolant solution to avoid rust forming on the internal surfaces. If the engine will be exposed to freezing temperatures, ensure that the closed‑cooling section is filled with a properly mixed antifreeze/coolant solution to protect the engine and closed‑cooling system to the lowest temperature to which they will be exposed.

NOTE: It is recommended that a 50/50 solution of coolant (antifreeze) and deionized, purified water be used. A 50/50 solution will provide freeze protection to –35° C (–31° F). Decreasing the solution to 40/60 will provide freeze protection to –25° C (–13° F). Even in the warmest climates, never decrease the solution below 40/60. Increasing the solution to 60/40 will provide freeze protection to –50° C (–58° F).

IMPORTANT: The antifreeze/coolant used in these marine engines must be a low silicate ethylene glycol, containing special additives, and deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer to the coolant manufacturer's instructions.

The acceptable antifreeze/coolants is listed in the following table. Refer to Section 5 ‑ Maintenance for respective change intervals.

Tube Ref No. Description Where Used Part No.

122

Extended Life Antifreeze/Coolant Closed-cooling system 92-877770K1

Engine Oil

NOTICE

Discharge of oil, coolant, or other engine/drive fluids into the environment is restricted by law. Use caution not to spill oil, coolant, or other fluids into the environment when using or servicing your boat. Be aware of the local restrictions governing the disposal or recycling of waste, and contain and dispose of fluids as required.

To optimize the performance of this engine in marine applications, Mercury strongly recommends the use of Quicksilver 5W‑30 Full Synthetic TDI Engine Oil. This oil meets international ACEA C3 specifications.

Engine Oil

2.0L System Capacity Fluid Type Part Number

Engine oil (with filter) 5.2 L (5.5 US qt) 5W‑30 Full Synthetic TDI Engine Oil 92‑8M0069603

Engine Specifications ‑ Inboard Models

Description Engine type In‑line 4‑cylinder diesel Induction Type Turbocharged and aftercooled 16‑valve Displacement 2.0L (122 cid) Firing order 1‑3‑4‑2 Bore 83 mm (3.27 in.) Stroke 92 mm (3.62 in.)

Rated engine RPM (Refer to Conditions Affecting Operation—Propeller Selection for additional information)

Idle RPM in neutral (engine at normal operating temperature) 700 RPM Oil pressure at idle 2.4 bar [240 kPa] (35 psi) Oil pressure at 4000 RPM 6.6 bar [660 kPa] (95 psi) Thermostats (water) 83° C (181° F) Thermostats (oil) 95° C (203° F) Coolant temperature 80–85° C (176–185° F) Electrical system 12‑volt negative (–) ground Alternator rating 14 V, 110 A Recommended battery rating* 750 CCA, 950 MCA, or 180 Ah

Specifications

3000 RPM

(115 HP only)

4000 RPM

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Section 3 - Specifications

*Battery manufacturers may rate and test their batteries to different standards. MCA, CCA, Ah, and reserve capacity (RC) are the ratings recognized by Mercury Marine. Manufacturers that use standards different than these, such as equivalent MCA, do not meet Mercury Marine battery requirements.

Fluid Specifications

IMPORTANT: All capacities are approximate fluid measures.

Engine

IMPORTANT: Fluid level indicators are calibrated to provide accurate readings with the engine level and installed according to the manufacturer's instructions. Modifications may affect fluid level readings.

Always use the proper fluid level indicator to determine the exact quantity of oil or fluid required.

Engines with Closed‑Cooling System Oil Cooler

2.0L System Capacity Fluid Type Part Number Engine oil (with filter) 5.2 L (5.5 US qt) 5W‑30 Full Synthetic TDI Engine Oil 92‑8M0069603 Closed‑cooling system 7.7 L (8.1 US qt) Extended Life Coolant/Antifreeze – concentrated 92‑8M0070979

Transmission

NOTE: Capacities are for the transmission only and do not include the fluid cooler or fluid cooler hose capacities.

Model

Technodrive TM 345 1.6 L (1.7 US qt )

Technodrive TM 485‑A

Capacity Fluid type Part Number

2.6 L (2.75 US qt )

Class CD SAE 20 or Class CD SAE 30 engine oil

SAE 20W ‑ 40 or SAE 15W ‑ 40 engine oil

Obtain locally

Approved Paints

Description Mercury Diesel White 8M0108939 Mercury Light Gray Primer 92‑80287852 Mercury Phantom Black 92‑802878Q1

Part Number

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Table of Contents

Section 4 - Maintenance

Owner and Operator Responsibilities................................... 28

Dealer Responsibilities......................................................... 28

Maintenance......................................................................... 28

Do‑It‑Yourself Maintenance Suggestions............................. 28

General Inspection............................................................... 28

Engine Cover........................................................................ 29

Removal.........................................................................29

Cleaning.........................................................................29

Inspection...................................................................... 29

Installation......................................................................29

Maintenance Schedule......................................................... 29

Routine Maintenance..................................................... 29

Scheduled Maintenance................................................ 30

Engine Oil............................................................................. 31

Specifications.................................................................31

Oil Level—Overfilled...................................................... 31

Checking........................................................................ 31

Filling............................................................................. 32

Changing Oil and Filter.................................................. 32

TM 345 Technodrive Transmission Fluid............................. 34

Checking........................................................................ 34

Filling............................................................................. 35

Changing....................................................................... 35

TM 485‑A Technodrive Transmission Fluid.......................... 37

Check Fluid.................................................................... 37

Add Fluid........................................................................38

Change Fluid................................................................. 38

Engine Coolant..................................................................... 40

Checking and Filling the Closed‑Cooling System.......... 40

Draining the Closed‑Cooling System............................. 42

Air Filter................................................................................ 43

Removal.........................................................................43

Inspection...................................................................... 44

Installation......................................................................44

Water‑Separating Fuel Filter................................................ 45

Draining......................................................................... 45

Replacing....................................................................... 46

Filling............................................................................. 48

Fuel System.......................................................................... 49

Priming...........................................................................49

Filling (Bleeding)............................................................ 49

Fuel Tank Cleaning and Flushing.................................. 49

Seawater System................................................................. 49

Draining the Seawater System...................................... 49

Checking the Seawater Pickups.................................... 51

Cleaning the Seawater Strainer..................................... 51

Engine Seawater Pump Inspection................................53

Corrosion Protection............................................................. 53

General Information....................................................... 53

Engine Corrosion Protection Components.................... 53

Removal ................................................................ 53

Cleaning and Inspection ........................................ 54

Installation ............................................................. 55

Antifouling Paint............................................................. 55

Lubrication............................................................................ 55

Throttle Cable................................................................ 55

Shift Cable..................................................................... 56

Drive Belts............................................................................ 56

Power‑Assisted Steering Pump Belt Inspection............ 56

Serpentine Belt Inspection............................................. 57

Battery.................................................................................. 58

Battery Precautions for Multiple Engines ...................... 58

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Section 4 - Maintenance

Owner and Operator Responsibilities

It is the operator's responsibility to perform all safety checks, to ensure that all lubrication and maintenance instructions are complied with for safe operation, and to return the unit to a Mercury Diesel authorized repair facility for a periodic checkup.

Normal maintenance service and replacement parts are the responsibility of the owner or operator and, as such, are not considered defects in workmanship or material within the terms of the warranty. Individual operating habits and usage contribute to the need for maintenance service.

Proper maintenance and care of your power package will ensure optimum performance and dependability and will keep your overall operating expenses at a minimum. See your Mercury Diesel authorized repair facility for service aids.

Dealer Responsibilities

It is the dealer's responsibility to provide predelivery inspection and preparation:

• Before delivery, making certain that the Mercury power package is in proper operating condition.

• Making all necessary adjustments for maximum efficiency.

• Explaining and demonstrating the operation of the power package and the boat.

• Providing a copy of the Predelivery Inspection Checklist.

• Completing the warranty registration and immediately submitting it to Mercury Marine via MercNET, e‑mail, or mail. All power packages must be registered for warranty purposes.

Maintenance

WARNING

Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or death due to fire, explosion, electrical shock, or unexpected engine starting. Always disconnect the battery cables from the battery before maintaining, servicing, installing, or removing engine or drive components.

WARNING

IMPORTANT: Refer to Maintenance Schedule for a complete listing of all scheduled maintenance to be performed. Some listings can be done by the owner or operator, while others should be performed by a Mercury Diesel authorized repair facility. Before attempting maintenance or repair procedures not covered in this manual, we recommended that you purchase the appropriate Mercury or Mercury MerCruiser Service Manual and read thoroughly.

NOTE: Maintenance points are color coded for ease of identification. Refer to the decal on the engine for identification.

• Blue—Coolant

• Yellow—Engine oil

• Orange—Transmission fluid

• Black—Gear lube oil

Do‑It‑Yourself Maintenance Suggestions

Mercury power packages are highly technical, complex pieces of machinery. Only qualified personnel using the proper tools should attempt major repair.

• Your safety is our concern. Always read and understand the Cautions, Warnings, Important Notices, and Notes.

• Do not attempt repairs unless specifically trained in that procedure.

• Reference the correct service manual for the product. Do not attempt repairs unless qualified.

• Special tools and equipment are required to perform certain repairs. Failure to use the correct special tools and equipment can result in severe damage to the product.

• Always have a Mercury Diesel authorized repair facility service your power package and do periodic maintenance inspections to help provide safe and trouble‑free boating.

General Inspection

Inspect your power package often and at regular intervals to help maintain its top operating performance and to correct potential problems before they occur. The entire power package should be checked carefully, including all accessible engine parts.

1. Check for loose, damaged, or missing parts, hoses, and clamps. Tighten or replace as necessary.

2. Check electrical connections and leads for damage or corrosion.

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3. Remove and inspect the propeller. If badly nicked, bent, or cracked, contact your Mercury Diesel authorized repair facility.

4. Repair nicks and corrosion damage on power package exterior finish. Contact your Mercury Diesel authorized repair

facility.

NOTE: A small panel in the engine cover allows access to the engine fuse panel, the engine oil fill cap, and the engine oil dipstick without removing the entire engine cover.

Engine Cover

Removal

1. Remove the engine fuse panel cover.

2. Lift straight up and detach the engine cover from the ball stud mounts.

3. Install the fuse panel cover to prevent loss.

Cleaning

1. Clean the engine cover with warm soapy water.

2. Air dry the cover.

Inspection

1. Inspect the engine cover for cracks or deterioration.

2. Inspect the rubber grommets for deterioration.

3. Inspect the hardware used with each grommet.

4. Replace damaged parts.

Installation

1. Remove the fuse panel cover.

2. Set the engine cover over the ball stud mounts.

3. Press the engine cover down above each mount to reattach the engine cover.

4. Replace the fuse panel cover.

Maintenance Schedule

Routine Maintenance

NOTE: Perform only the maintenance tasks that apply to your particular power package.

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Section 4 - Maintenance

• Check the engine oil level. (This interval can be extended based on operator experience with the

Each day start

Each day end

Weekly

Every Two Months

• Check the engine coolant level.

• Check the transmission oil level.

• If operating in saltwater, brackish water, or polluted water, flush the seawater section of the

• Drain any water from the primary fuel filter after each use. (Drain any water from both fuel filters

• Drain any water from the fuel filters.

• Check the seawater inlets for debris or marine growth.

• Check and clean the seawater strainer.

• Check the battery connections and fluid level.

• Treat the engine surfaces with Corrosion Guard if operating in saltwater, brackish water, or

• Inspect the air filter. (Inspect every two months or every 50 hours, whichever occurs first.)

• Inspect the engine anodes and replace if eroded by 50% or more.

• Ensure that the gauges and all wiring connections are secure.

• Clean the gauges. (If operating in saltwater reduce the interval to every 25 hours or 30 days,

Scheduled Maintenance

product.)

cooling system after each use.

if operating in freezing temperatures.)

polluted waters.

whichever occurs first.)

After first 50 hours

Annually

Every 100 hours or annually (whichever occurs first)

Every 200 hours or annually

(whichever occurs first)

Every 2 years

Every 1000 hours or 5 years (whichever occurs first)

According to OEM Schedule • Check the engine to propeller shaft alignment.

• Clean the transmission oil filter and change the transmission oil.

• Touch‑up the power package with paint and spray with Corrosion Guard.

• Clean the transmission oil filter and change the transmission oil.

• Check the steering system and the remote control for loose, missing, or damaged parts. Lubricate the cables and linkages.

• Check the engine alignment.

• Torque the engine mounts.

• Check the electrical system for loose, damaged, or corroded terminals.

• Inspect the cooling system and the exhaust system for damage or leaks. Check both systems hose clamps for tightness.

• Clean the transmission oil filter and change the transmission oil.

• Change the engine oil and filter.

• Replace the fuel filters.

• Replace the air filter.

• Inspect the condition and tension of the engine accessory drive belts.

• Disassemble and inspect the engine seawater pump and replace worn components.

• Check the seawater pump drive belt.

• Clean the seawater section of the closed cooling system. Clean, inspect, and test the pressure cap. Check the anodes and replace if eroded by 50% or more.

• Clean the seawater strainer.

• Check the closed cooling fluid level and level of protection.

• Check the run history for faults.

• Check the engine timing belt.

• Replace the engine coolant.

• Replace the engine timing belt.

• Clean the fuel tank.

• Clean the aftercooler core.

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Engine Oil

Specifications

Engine Oil

2.0L System Capacity Fluid Type Part Number

Engine oil (with filter) 5.2 L (5.5 US qt) 5W‑30 Full Synthetic TDI Engine Oil 92‑8M0069603

Oil Level—Overfilled

NOTICE

An overfilled engine crankcase or block can cause a fluctuation or drop in oil pressure. The overfull condition results in the engine crankshaft splashing and agitating the oil, causing it to become aerated. The aerated oil causes a loss of engine performance and an increase in crankcase back pressure. An extreme overfill condition could result in large amounts of oil being drawn into the intake.

Checking engine oil level must be done carefully. The oil level must be maintained between the minimum and the maximum oil level mark on the dipstick. To ensure that you are not getting a false reading, observe the following before checking the oil level.

• If the boat is in the water, ensure that the boat is at rest.

• If the boat is on a trailer, raise or lower the bow until the boat is sitting as it does at rest in the water.

• Allow five minutes for the oil to drain into the oil pan if the engine has just been operated or oil has just been added.

Checking

IMPORTANT: Engine crankcase oil must be checked at intervals specified in Maintenance Schedules. It is normal for an engine to use a certain amount of oil in the process of lubricating and cooling the engine. The amount of oil consumed depends greatly upon engine speed, with consumption being highest at wide‑open throttle and decreasing substantially as engine speed is reduced.

NOTICE

With the engine running, the crankshaft journals or rod journals may strike and break the dipstick, resulting in damage to internal engine components. Stop the engine completely before removing or inserting the dipstick.

1. To check the engine oil level during operation, stop the engine and allow five minutes for the oil to drain into the pan.

2. Remove the dipstick. Wipe clean and install into the dipstick tube.

2.0L engine oil service

a - Engine cover with access panel removed b - Engine oil fill cap c - Engine oil dipstick

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3. Remove the dipstick and observe the oil level. The oil level must be between the marks on the dipstick. If necessary, add oil. Refer to Filling.

Engine oil level markings

a - Dipstick b - Minimum operating level c - Full mark and maximum operating level

14624

4. Install engine oil dipstick.

Filling

IMPORTANT: Do not overfill the engine with oil.

1. Remove the oil fill cap.

2.0L engine oil service

a - Engine cover with access panel removed b - Engine oil fill cap c - Engine oil dipstick

2. Add the specified oil to bring the oil level up to, but not over, the maximum mark on the dipstick.

Engine Oil

2.0L System Capacity Fluid Type Part Number

Engine oil (with filter) 5.2 L (5.5 US qt) 5W‑30 Full Synthetic TDI Engine Oil 92‑8M0069603

IMPORTANT: When filling the engine with oil, always use the dipstick to confirm the oil level.

3. Install the oil fill cap.

Changing Oil and Filter

Refer to the Maintenance Schedule for the change interval. Change the engine oil before placing the boat in storage. IMPORTANT: Change the engine oil when the engine is warm from operation. Warm oil flows more freely, carrying away more

impurities. Use only recommended engine oil.

Engine Oil

2.0L System Capacity Fluid Type Part Number

Engine oil (with filter) 5.2 L (5.5 US qt) 5W‑30 Full Synthetic TDI Engine Oil 92‑8M0069603

1. Start the engine and allow it to warm up to normal operating temperature.

2. Stop the engine and allow the oil to drain into the oil pan for approximately five minutes.

3. Place a suitable container under the oil filter housing to capture any spilled oil. Use an appropriate socket to loosen the oil filter cover.

4. Remove the drain plug on the oil filter housing and allow to drain into a suitable container.

5. Remove the oil filter cover and oil filter.

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6. Discard the oil filter and O‑ring.

a - Drain plug b - Oil filter cover c - O‑ring d - Oil filter

7. Apply sealant to the threads of the oil filter housing drain plug and install.

Tube Ref No. Description Where Used Part No.

8. Tighten the oil filter housing drain plug to the specified torque.

Description Nm lb‑in. lb‑ft Drain plug 19 168 –

9. Install a new O‑ring onto the oil filter cover and lubricate with engine oil.

10. Push the filter element into the cover until it is locked. Listen for a click.

11. Install the oil filter housing cover onto the oil filter housing and tighten to the specified torque.

IMPORTANT: Overtightening the cover may cause an oil leak.

Loctite 567 PST Pipe Sealant Drain plug threads 92-809822

Engine Coolant Oil Cooler

Engine Coolant Oil Cooler Description Nm lb‑in. lb‑ft Engine oil filter housing cover 25 – 18

12. Remove the dipstick.

a - Oil fill cap b - Dipstick

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11591

13. Locate the crankcase oil drain hose and remove the cap.

14. Install the crankcase oil pump (order separately) onto the crankcase oil drain hose.

Crankcase Oil Pump 91‑ 802889Q 1

Aids in the removal of engine oil without draining the crankcase.

15. Pump the oil out of the crankcase into an appropriate container.

16. Remove the crankcase oil pump and install the cap onto the crankcase oil drain hose and tighten securely.

17. Install the oil dipstick.

18.

Remove the oil fill cap and fill the engine with oil. Refer to Filling. IMPORTANT: When filling the engine with oil, always use the dipstick to determine how much oil is required.

19. Replace and secure the oil fill cap.

20. Start the engine and check for leaks.

21. Dispose of the waste oil, filter, and O‑ring as directed by local ordinances.

TM 345 Technodrive Transmission Fluid

Checking

1. Remove the dipstick.

2. Perform a preliminary check the oil level as indicated on the dipstick with the dipstick fully inserted into the dipstick receptacle.

NOTE: The oil level may be somewhat over the maximum mark, as some of the oil from the transmission oil cooler and hoses may have drained back into the transmission.

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MIN

MAX

27922

MIN

MAX

If the oil level is below the minimum mark on the dipstick, add transmission oil. See Filling.

a - Minimum oil level b - Maximum oil level c - Dipstick

4. Clean and install the dipstick.

IMPORTANT: To ensure an accurate indication of the oil level, operate the engine at 1500 RPM for two minutes immediately before checking the oil level.

5. Start the engine and operate at 1500 RPM for two minutes to reach operating temperature and fill all of the transmission's

hydraulic circuits.

6. Stop the engine and quickly check the oil level with the dipstick.

If the oil level is low, add transmission oil to bring the level up to the maximum mark on the dipstick. See Filling.

NOTE: If the transmission oil level was extremely low, see your local Mercury Diesel authorized repair facility.

8. Clean and install the dipstick.

Filling

1. If necessary, add the specified transmission oil through the dipstick receptacle to bring the level up to the maximum mark

on the dipstick.

a - Minimum oil level b - Maximum oil level c - Dipstick

NOTE: Always use the dipstick to determine the quantity of oil required.

Model

Technodrive 345‑A 1.6 L (1.7 US qt)

2. Clean and install the dipstick.

Check the oil level. Refer to Checking.

Capacity Fluid type Part Number

API Class CD SAE 20 or API Class CD SAE 30 engine oil

Obtain Locally

Changing

1. Remove the dipstick.

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Section 4 - Maintenance

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2. Remove the transmission oil drain plug and drain the transmission into a suitable container.

Transmission drain plug

3. Contain and dispose of the oil and oil waste according to applicable regulations.

4. Reinstall the transmission oil drain plug.

5. Tighten the drain plug to the specified torque.

Description

Nm lb‑in. lb‑ft

Transmission oil drain plug 17 150 –

6. Clean the exterior of the transmission around the oil filter assembly.

7. Loosen the retaining nut.

Transmission oil filter retaining nut

8. Remove the filter element.

9. Clean the oil filter element using the cleaning solvent.

Tube Ref No.

Cleaning solvent Transmission filter element Obtain Locally

Description Where Used Part No.

10. Lubricate the oil filter O‑rings.

Tube Ref No.

SAE engine oil 30W Transmission filter element O-ring Obtain Locally

Description Where Used Part No.

11. Reinstall the filter element.

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Section 4 - Maintenance

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NOTICE

Improper installation of the transmission fluid filter assembly may cause the fluid to foam or leak out, resulting in decreased efficiency and damage to the transmission. Properly seat the transmission fluid filter during installation.

12. Tighten the retaining nut.

13.

Fill the transmission to the proper level with the specified oil. See Filling.

TM 485‑A Technodrive Transmission Fluid

Check Fluid

1. Remove the dipstick.

IMPORTANT: When checking the fluid level, rest the dipstick on top of the threaded housing hole. Do not screw the dipstick onto the threaded housing hole.

2. Check the fluid level as indicated on the dipstick with the dipstick resting on the top of the threaded hole.

NOTE: The fluid level may be somewhat over the maximum mark, as some of the fluid from the transmission fluid cooler and hoses may have drained back into the transmission.

If the fluid level is below the minimum mark on the dipstick, add transmission fluid. See Add Fluid.

a - Dipstick b - Maximum fluid level c - Minimum fluid level

IMPORTANT: To accurately check the fluid level, operate the engine at 1500 RPM for two minutes immediately before checking the level.

4. Start the engine and operate at 1500 RPM for two minutes to fill all the hydraulic circuits.

5. Stop the engine and quickly check the fluid level with the dipstick resting on the top of the threaded hole.

If the fluid level is low, add transmission fluid to bring the level up to the maximum mark on the dipstick. See Add Fluid.

NOTE: If the transmission fluid level was extremely low, see your local Mercury Diesel authorized repair facility.

7. Install the dipstick.

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Section 4 - Maintenance

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24623

Add Fluid

1. If necessary, add specified transmission fluid through the dipstick threaded hole to bring the level up to the maximum mark on the dipstick.

a - Dipstick b - Maximum fluid level c - Minimum fluid level

NOTE: Always use the dipstick to determine the quantity of oil or fluid required.

Model

Technodrive 485A 2.6 L (2.7 US qt)

2. Install the dipstick.

Check the fluid level. Refer to Check Fluid.

Capacity Fluid type Part Number

SAE 20W ‑ 40 or SAE 15W ‑ 40 engine oil

Obtain Locally

Change Fluid

NOTICE

1. Remove the fill cap and dipstick.

2. Remove the transmission fluid drain plug and drain the transmission into a suitable container.

a - Fill cap and dipstick b - Drain plug

3. Dispose of the waste according to local regulations.

4. Reinstall the transmission fluid drain plug.

5. Tighten the drain plug to the specified torque.

Description Transmission fluid drain plug 17 150

Nm lb‑in. lb‑ft

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6. Clean the exterior of the transmission around the fluid filter assembly.

24608

24618

7. Loosen the assembly nut, and rotate the securing tab in the direction shown.

a - Assembly nut b - Securing tab

8. Remove the filter element.

a - Filter element

Section 4 - Maintenance

9. Clean the filter element with a mild cleaning solvent, obtained locally.

10. Lubricate the O‑rings with SAE Engine Oil 30W.

Tube Ref No.

SAE Engine Oil 30W Transmission filter element O-ring Obtain Locally

Description Where Used Part No.

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Section 4 - Maintenance

24620

24621

11. Reinstall the filter element.

a - Filter element b - O‑ring

NOTICE

12. Replace the securing tab over the filter assembly by turning it clockwise.

13. Tighten the assembly nut to the specified torque.

a - Assembly nut b - Securing tab

Description Nm lb‑in. lb‑ft Assembly nut 5–8 48–72 –

14.

Fill the transmission to the proper level with the specified fluid. See Add Fluid.

Engine Coolant

CAUTION

A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.

Checking and Filling the Closed‑Cooling System

1. Allow the engine to cool.

2. Remove the pressure cap from the coolant expansion tank.

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3. The coolant level in the coolant expansion tank should be within25 mm (1 in.) of the top of the fill neck.

2.0L (engine cover removed)

a - Pressure cap b - Coolant expansion tank c - Coolant fill neck

IMPORTANT: Use only the specified coolant. The coolant must be mixed with water at the ratio specified in Section 4– Antifreeze/Coolant.

Tube Ref No. Description Where Used Part No.

122

4. If the coolant level is low: a. Inspect the coolant recovery system for leaks. b. Inspect the gasket in the pressure cap for damage and replace if necessary.

Extended Life Antifreeze/Coolant Closed-cooling system 92-877770K1

a - Gasket

14142

c. The pressure cap maintains pressure on the cooling system and may not be holding pressure properly. To have the

cap tested, contact your Mercury Diesel authorized repair facility.

5. Slowly add the coolant within 25 mm (1 in.) of the top of the expansion tank filler neck.

If the boat is out of the water, both the engine and sterndrive must be supplied with cooling water. Refer to Flushing the Seawater System section of this manual.

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

7. Do not install the pressure cap. Start and operate the engine at fast idle speed between 600–1400 RPM. Add coolant as

necessary to maintain the coolant at the level specified previously.

8. Install the pressure cap after the engine has reached normal operating temperature (with the thermostat fully open) and the

coolant level remains constant.

IMPORTANT: When installing the pressure cap, be sure to tighten it securely to avoid coolant loss.

9. Test the engine operation. Observe the temperature gauge and check the engine for coolant leaks. If the temperature

gauge indicates the presence of excessive temperature or coolant is leaking, stop the engine immediately and inspect for the cause.

10. After the first operation, allow the engine to cool.

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11. Remove the pressure cap and add coolant to the specified level.

12. Install and securely tighten the pressure cap.

Draining the Closed‑Cooling System

IMPORTANT: Due to the complex nature of this service Mercury Diesel strongly recommends that this service be performed by a Mercury Diesel authorized repair facility.

NOTICE

NOTE: For instructions on draining the seawater section, refer to

IMPORTANT: Observe the following points:

• Ensure that the engine is as level as possible to promote complete draining of the cooling system.

• The closed‑cooling section must be filled year‑round with the required coolant. If the engine will be exposed to freezing temperatures, ensure that the closed‑cooling section is filled with a solution of low silicate ethylene glycol antifreeze and deionized, purified water properly mixed to protect the engine to the lowest temperature to which it will be exposed.

• Do not use propylene glycol antifreeze in the closed‑cooling section of the engine.

A sudden loss of pressure can cause hot coolant to boil and discharge violently resulting in serious injury from burns. Allow the engine to cool down before removing the coolant pressure cap.

1. Allow the engine to cool.

2. Remove the pressure cap from the expansion tank and coolant reservoir.

Remove the fuel filter for access to the engine coolant drain plug. Refer to Water‑Separating Fuel Filter.

4. If the engine has the optional fuel cooler installed, move the fuel lines so they do not obstruct access to the engine coolant drain plug.

Draining the Seawater System

CAUTION

Port side of engine

a - Throttle cable bracket b - 14‑pin electrical connector c - Water‑separating fuel filter d - Fuel cooler with fuel lines moved to provide access (if

equipped)

e - General location of engine coolant drain plug f - Engine control module

in this section.

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5. Remove the engine coolant drain plug and drain the coolant into a suitable container. Allow the engine coolant system to drain completely. Dispose of the coolant according to local laws.

Port side of block with water-separating fuel filter removed for access

a - Engine coolant drain

plug

6. Ensure that the coolant has drained completely.

7. If required, clean the closed‑cooling system. See your local Mercury Diesel authorized repair facility.

8. Install and tighten the engine coolant drain plug.

Install the water‑separating fuel filter. Refer to Water‑Separating Fuel Filter, Replacing.

10.

Fill the system with the specified coolant. Refer to Checking and Filling the Closed‑Cooling System.

Air Filter

Removal

1. Loosen the clamp and remove the oil separator vent hose.

2. Loosen the clamp and remove the air filter housing from the turbocharger inlet.

Air filter housing on engine

a - Oil separator vent hose clamp b - Air filter element c - Air filter housing clamp

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3. Remove the air filter element from the air filter housing.

a - Air filter element b - Air filter housing

Inspection

1. The air filter cannot be cleaned. Replace the air filter if it is dirty or contaminated.

2. Replace the air filter if the foam element is deteriorated or torn.

Replace the air filter at the recommended interval. See Maintenance Schedules for the replacement interval under normal conditions.

Installation

IMPORTANT: The air filter element is an integral component and must be clean and dry for proper filtration and engine performance. Do not apply oil to the air filter element.

1. Slide the air filter element onto the air filter housing. Ensure that the element covers all of the holes on the air filter housing.

a - Air filter element b - Air filter housing

2. Install the air filter housing onto the turbocharger inlet.

3. Tighten the air filter housing clamp to the specified torque.

Description Air filter housing clamp 5.6 50 –

4. Install the oil separator vent hose.

Nm lb‑in. lb‑ft

a - Oil separator vent hose clamp b - Air filter element c - Air filter housing clamp

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5. Tighten the oil separator vent hose clamp to the specified torque.

Description Nm lb‑in. lb‑ft Oil separator vent hose clamp 5.6 50 –

Water‑Separating Fuel Filter

WARNING

Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start. Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel immediately.

NOTICE

Water entering the fuel injection system will cause corrosion and rusting of the injectors and other components, disabling the fuel injection system. Check daily for water in the water‑separating fuel filter and have the engine inspected immediately if there is evidence of water in the fuel system.

IMPORTANT: Use a suitable container to collect fuel. Clean up any spills immediately and dispose of fuel in a safe manner in accordance with all local, federal, and international regulations.

The engine‑mounted water‑separating fuel filter is equipped with a water‑in‑fuel (WIF) sensor that should alert the operator when water is present in the filter. This fuel filter needs to be replaced at specified intervals or whenever water is detected in the fuel, whichever comes first.

The operator may be alerted that the WIF sensor has detected water in the fuel, depending upon the boat instrumentation package and if equipped:

• A fault code may be displayed on a system viewer.

• The audio warning system may sound. See Features and Controls. Drain or replace the remote mounted primary filter (such as a Racor® filter) at specified intervals, or whenever water is

detected in the engine‑mounted fuel filter.

Draining

The engine‑mounted water‑separating fuel filter can be drained of water and small dirt particles by opening the drain cap on the bottom of the filter.

NOTE: To ensure complete draining in warm weather, drain the filter before starting daily operations. In cold weather, where there is a possibility that the condensed water will freeze, drain the filter shortly after the end of daily operations.

NOTE: Place a suitable container under the fuel filter to catch contaminated fuel or water. Dispose of properly.

1. Place a container under the drain cap on the filter.

2. Open the drain by turning the drain cap counterclockwise (as viewed from the bottom of the filter) until fuel starts draining. Do not remove the drain cap.

Typical water-separating fuel filter

a - WIF sensor wire connection b - Filter c - Drain cap

3. Drain until the fuel is clear in appearance.

4. Close the drain cap by turning clockwise. Tighten securely.

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Fill the fuel filter. See Filling.

Replacing

WARNING

IMPORTANT: The element cannot be cleaned and reused. It must be replaced.

1. Disconnect both battery cables from the battery.

2. Disconnect the WIF sensor wires, if equipped.

3. Remove the water‑separating fuel filter and sealing ring from the mounting bracket. Do not use a filter wrench.

Typical

a - Water‑separating fuel filter

NOTE: It may be necessary to keep the existing drain cap and use it on the new filter. Be sure to replace the O‑ring on the drain cap.

4. Remove the drain cap and O‑ring seal from the bottom of the existing fuel filter. Note the position of the O‑ring seal.

Typical

a - Drain cap b - O‑ring seal

5. Discard the used filter and O‑ring seal as defined by local authorities.

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6. Install the O‑ring and drain cap on the new water‑separating fuel filter.

24568

24569

23460

Typical

a - Drain cap b - O‑ring seal

7. Lubricate the fuel filter seals with SAE engine oil 30W.

Typical

a - Water‑separating fuel filter b - Seals

Section 4 - Maintenance

Tube Ref No. Description Where Used Part No.

8. Align the filter to the bracket. Twist the filter by hand to secure the filter to the bracket. Do not use a filter wrench.

9. Ensure that the drain cap is securely tightened.

10. Connect the WIF sensor wires, if equipped.

11.

Fill the water‑separating fuel filter with fuel. Refer to Filling.

12. Check the filter and drain cap for fuel leaks.

13. Connect the battery cables.

14. Start and operate the engine. Check the filter connection for fuel leaks. If leaks exist, recheck the filter installation. If leaks continue, stop the engine immediately and contact your Mercury Diesel authorized repair facility.

SAE Engine Oil 30W Water-separating fuel filter sealing ring Obtain Locally

Typical

a - Water‑separating fuel filter

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Filling

A type of hand pump and primer plunger is located on the fuel filter bracket and is used to

• Refill the fuel filter when draining or changing the filter.

• Refill the fuel system on the engine if the system was run dry.

• Prime the fuel system if the engine has not been run for an extended period. IMPORTANT: Only fill the fuel filter with the hand pump and primer plunger to ensure that unfiltered fuel does not get into the fuel system.

NOTE: Follow this procedure after installing a new filter or if the fuel has been drained from the filter checking for water.

1. Loosen the air vent (bleed) screw on the fuel filter bracket.

Typical

a - Air vent screw

2. Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw.

Typical

a - Air vent screw b - Primer plunger

3. Securely tighten the air vent screw.

Typical

a - Air vent screw

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Fuel System

Priming

Prime the engine if it has not been run for an extended period or if the engine will not start.

1. Move the primer plunger up and down repeatedly.

a - Fuel priming pump

2. Attempt to start the engine.

Filling (Bleeding)

NOTE: Follow this procedure if the fuel system was run dry or if part of the fuel system was drained for a service function.

See Water Separating Fuel Filter ‑ Filling and fill the fuel filter.

2. Check the filter and drain cap for fuel leaks. Ensure that the bleed screw on the fuel filter bracket is closed.

Fuel Tank Cleaning and Flushing

IMPORTANT: Diesel fuel should not be left in the tank during winter storage, as an accumulation of rust, sludge, and wax residue will form.

Refer to the boat manufacturer's instructions and clean the fuel tank at specified intervals. Unless specified otherwise, flush and clean the diesel fuel tank every 1000 hours or five years, whichever occurs first.

Seawater System

Draining the Seawater System

CAUTION

Water can enter the bilge when the drain system is open, damaging the engine or causing the boat to sink. Remove the boat from the water or close the seacock, disconnect and plug the seawater inlet hose, and ensure the bilge pump is operational before draining. Do not operate the engine with the drain system open.

IMPORTANT: The engine must be as level as possible to ensure complete draining of the seawater system. Drain the seawater system before flushing or prior to cold weather (freezing temperature), seasonal storage, or extended

storage. IMPORTANT: The engine must not be operating during this procedure.

CAUTION

1. Remove the boat from the water if possible.

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If the boat is to remain in the water, turn on the bilge pump, close the seacock (if equipped), or disconnect and plug the seawater inlet hose.

Typical seacock installation

3. Make the engine as level as possible to ensure complete draining of the seawater system.

4. Attach a temporary drain hose to the barbed fitting of the seawater drain valve.

Coolant oil cooler

a - Seawater drain valve b - Oil filter housing

5. Open the seawater drain valve.

6. A small diameter wire bore brush or stiff piece of wire can be used to clear the seawater drain valve of any debris.

7. Disconnect the seawater inlet hose from the connector on the seawater pump.

a - Seawater pump inlet b - Seawater pump c - Seawater pump outlet d - Fuel cooler (if equipped)

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On models equipped with a seawater strainer, remove the hoses at the seawater strainer and drain them completely. Drain and empty the seawater strainer. Connect the hoses and tighten the hose clamps securely.

Typical

a - Seawater inlet b - Seawater outlet c - Seawater strainer cover

9. After the seawater has completely drained, remove the temporary drain hose and close the heat exchanger seawater drain valve.

10. Connect all seawater hoses.

11. Tighten all hose clamps to the specified torque.

Description Hose clamp 5.6 50 –

Checking the Seawater Pickups

1. Ensure that the water inlet holes for the seawater pickup are clean and not obstructed.

Typical through-hull seawater pickup

a - Water inlet holes

Typical through-transom seawater pickup

Cleaning the Seawater Strainer

NOTE: Visually inspect the seawater strainer through its clear cover.

Nm lb‑in. lb‑ft

16776

NOTICE

An open seawater strainer or seacock during some service or maintenance procedures can introduce water into the boat, causing damage or sinking the boat. Always close the water supply from the seawater pump, water inlet, or seacock when performing service or maintenance on the cooling system.

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NOTICE

Disconnecting the seawater inlet hose will cause water to enter the bilge resulting in engine damage. Close the seacock before disconnecting the seawater inlet hose. Plug the seawater inlet hose immediately after disconnecting it.

1. If the boat is in the water, ensure that the engine is off and close the seacock, if equipped, or remove and plug the seawater inlet hose.

2. Remove the seawater strainer cover by turning it counterclockwise by hand.

a - Seawater inlet b - Seawater outlet c - Seawater strainer cover

3. Remove the strainer from the strainer housing and clean out any debris. Flush the strainer with clean water.

4. Clean out any debris from the strainer housing and flush with clean water.

5. Place the strainer back into strainer housing. Ensure that it is fully and evenly seated into the bottom of the strainer housing.

6. Inspect the strainer cover's O‑ring seal and replace if damaged or leaking.

7. Install the strainer cover by turning it clockwise by hand. Ensure that the strainer cover O‑ring is properly located and moderately compressed when the cover is installed. Do not overtighten.

a - Seawater inlet b - Seawater outlet c - Seawater strainer cover

8. If the boat is out of the water. Perform an operational inspection of the seawater cooling system after cleaning the seawater strainer.

Cooling water must be supplied to the engine seawater pump. Refer to Flushing the Seawater System regarding cooling water supply when this service is performed with the boat out of the water.

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b. Start the engine and allow the seawater system to fill and the engine to reach normal operating temperature. c. Run the engine at a fast idle between 600 and 1400 RPM. Monitor engine temperature to confirm proper operation of

the cooling system. d. Inspect the seawater system for leaks maintaining a fast idle engine speed between 600 and 1400 RPM. e. Tag the keys, record the service in the maintenance log, or otherwise make note that a proper operational inspection

of the seawater system must be performed before returning the boat to service.

9. If the boat is in the water, perform an operational inspection of the seawater cooling system. a. Open the seacock, if equipped, or remove the plug and reconnect the seawater inlet hose. b. Start the engine and allow the seawater system to be filled and the engine to reach normal operating temperature. c. Check the seawater cooling system for leaks within an RPM range of 600 to 1400 RPM. d. Carefully monitor the engine operating temperature to ensure that it remains in normal operational range and that the

seawater cooling system is functioning properly.

Engine Seawater Pump Inspection

IMPORTANT: Mercury strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Remove and inspect the engine seawater pump at the interval specified in the Maintenance Schedule. See your Mercury

Diesel authorized repair facility.

Corrosion Protection

General Information

Whenever two or more dissimilar metals (such as those found on this power package) are submerged in a conductive solution such as saltwater, polluted water, or water with a high mineral content, a chemical reaction takes place causing electrical current to flow between metals. The electrical current flow causes the metal that is most chemically active, or anodic, to erode. This erosion is known as package components exposed to water.

To help control the effects of galvanic corrosion, Mercury power packages come with several sacrificial anodes and other corrosion protection devices. For a more comprehensive explanation of corrosion and corrosion protection refer to the Marine Corrosion Protection Guide.

IMPORTANT: Replace sacrificial anodes if eroded 50% or more. Mercury strongly recommends avoiding the use of anodes from other manufacturers. Refer to your Mercury Diesel authorized repair facility for additional information.

galvanic corrosion

and, if it is not controlled, it will eventually cause the need for replacement of power

Engine Corrosion Protection Components

The engine is equipped with a sacrificial anode located in the end cover of the engine aftercooler to assist in protecting the engine and the seawater cooling system from corrosion.

Removal

1. Allow the engine to cool.

NOTICE

Failure to close the seawater inlet or seacock when removing or replacing the anode plugs can lead to water damage. Close the seacock or remove and plug the seawater inlet hose to prevent water from entering the anode plug holes.

2. With the engine off, close the seacock, if equipped, or remove and plug the seawater inlet hose.

Drain the seawater system. Refer to Draining the Seawater System.

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abcde

4. Remove the anode assembly (anode plug, sealing washer, and the sacrificial anode) from the aftercooler end cover.

Seawater system anode assembly location

Cleaning and Inspection

NOTE: Use sandpaper, fiber brush, or a cleaning pad to remove the deposits from the surface of the anode before trying to determine the amount of erosion. Do not use a steel brush which might leave deposits that could accelerate corrosion.

1. Remove the deposits.

2. Inspect and measure the anode. Compare the measurements to the specifications for a new sacrificial anode and replace the anode assembly when deteriorated 50%.

NOTE: Sacrificial anodes are available only as an assembly. Replace both the plug and anode as a unit.

Anode assembly

a - Anode plug b - Sacrificial anode c - Length d - Diameter e - Sealing washer

19226

Sacrificial anode measurements (new) Length 19 mm (3/4 in.) Diameter 16 mm (5/8 in.)

3. Discard the sealing washer.

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Installation

1. Install a new sealing washer on the anode assembly (anode plug with the sacrificial anode).

a - Anode assembly b - Sealing washer

19227

2. Install the anode assembly and washer into the aftercooler end cover. Tighten securely.

3. Unplug and connect the seawater inlet hose, or open the seacock if equipped.

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

4. Ensure that both the sterndrive and engine seawater pickup pumps are supplied sufficient cooling water.

5. Start the engine and check for leaks.

Antifouling Paint

IMPORTANT: Corrosion damage that results from the improper application of anti‑fouling paint is not covered by the limited warranty.

In some areas it may be advisable to paint the bottom of the boat to help prevent marine growth. Contact a Mercury Diesel authorized repair facility for recommendations for your boat.

Lubrication

Throttle Cable

1. Lubricate the pivot points and guide contact surfaces.

a - Pivot points b - Guide contact surfaces

Tube Ref No. Description Where Used Part No.

SAE Engine Oil 30W Throttle cable pivot points and guide contact surfaces Obtain Locally

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Shift Cable

Lubricate the pivot points and guide contact surfaces.

Typical inboard model shift cable and transmission linkage

a - Pivot points b - Guide contact surface

13347

Tube Ref No. Description Where Used Part No.

SAE Engine Oil 30W Shift cable pivot points and guide contact surfaces Obtain Locally

Drive Belts

All drive belts must be periodically inspected for tension and condition, such as excessive wear, cracks, fraying, or glazed surfaces.

WARNING

Inspecting the belts with the engine running may cause serious injury or death. Turn off the engine and remove the ignition key before adjusting tension or inspecting belts.

2.0L front cover removed

a - Serpentine belt b - Power‑assisted steering belt

Power‑Assisted Steering Pump Belt Inspection

The 2.0 diesel engine uses a stretch‑belt to drive the power‑assisted steering pump. The stretch‑belt is engineered to have a certain amount of elasticity and designed to have self tensioning and vibration damping characteristics not found in standard serpentine accessory drive belts. Stretch‑belt service and maintenance procedures differ from standard accessory drive belts. Should the power‑assisted steering pump stretch‑belt need replacement, consult your Mercury Diesel authorized repair facility.

1. Inspect the power–assisted steering stretch‑belt for the following:

• Excessive wear

• Cracks

• Fiber fraying

• Glazed surfaces

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2. Replace the belt if worn or damaged it must be replaced. See your Mercury Diesel authorized repair facility.

a - Power–assisted steering stretch belt b - Power–assisted steering pump pulley c - Crankshaft pulley

3. There is no adjustment available for the power‑assisted steering pump stretch‑belt. If the belt becomes loose or noisy, it has worn out and must be replaced. See your Mercury Diesel authorized repair facility.

Serpentine Belt Inspection

The 2.0 diesel engine is equipped with a stretch‑belt that is used to drive the power‑assisted steering pump. This belt must be removed to service the serpentine belt. Stretch‑belt service and maintenance procedures differ significantly from those that apply to standard accessory drive belts. Should the serpentine belt need replacement, consult your Mercury Diesel authorized repair facility.

1. Inspect the serpentine belt for proper tension and for the following:

• Excessive wear

• Cracks

NOTE: Minor, transverse cracks (across the belt width) may be acceptable. Longitudinal cracks (in the direction of belt length) that join transverse cracks are not acceptable.

• Fraying

• Glazed surfaces

2. Check the operation of the automatic tensioner and associated components.

a. Position a suitable tool on the automatic tensioner pulley bolt.

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b. Rotate the automatic tensioner clockwise.

a - Serpentine belt b - Automatic tensioner c - Idler pulley d - Alternator e - Idler pulley f - Sea water pump pulley

c. Release the automatic tensioner allowing it to return to a load position on the serpentine belt. d. The automatic tensioner must return to the initial position and hold tension on the serpentine belt. If the automatic

tensioner does not operate smoothly or does not return to a loaded position providing tension on the belt, it must be replaced. See your Mercury Diesel authorized dealer for all of your repair needs.

3. There is no adjustment available for the serpentine belt. If the belt becomes loose or noisy, it has worn out and must be replaced. See your Mercury Diesel authorized repair facility.

4. Should the serpentine belt need replacement consult your Mercury Diesel authorized repair facility.

Battery

Refer to the specific instructions and warnings accompanying your battery. If this information is not available, observe the following precautions when handling a battery.

WARNING

Recharging a weak battery in the boat, or using jumper cables and a booster battery to start the engine, can cause serious injury or product damage from fire or explosion. Remove the battery from the boat and recharge in a ventilated area away from sparks or flames.

WARNING

An operating or charging battery produces gas that can ignite and explode, spraying out sulfuric acid, which can cause severe burns. Ventilate the area around the battery and wear protective equipment when handling or servicing batteries.

Battery Precautions for Multiple Engines

Alternators: Alternators are designed to charge a single battery that supplies electrical power to the individual engine on which the alternator is mounted. Connect only one battery to one alternator. Do not connect two batteries to the same alternator

unless a battery isolator is used. Engine Control Module (ECM) and Vessel Integration Panel (VIP). The ECM and VIP require a stable voltage source.

During multiple engine operation, an onboard electrical device may cause a sudden drain of voltage at the engine's battery. The voltage may drop below the ECM or VIP minimum voltage requirements. The alternator on the second engine may also start charging, causing a voltage spike in the engine's electrical system.

In either case, the ECM could shut off. When the voltage returns to the range that the ECM requires, the ECM will reset itself. The engine will now run normally. This ECM shut down usually happens so fast that the engine just appears to have an ignition miss. Intermittent or temporary VIP shutdown can cause a loss of instrumentation, engine misfire and can adversely effect power package performance and boat safety.

Batteries. Boats with multi‑engine electronic control power packages require each engine be connected to its own battery, ensuring that the engine's ECM has a stable voltage source.

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Battery Switches. Battery switches should always be positioned so that each engine is operating off of its own battery. Do not operate engines with switches in the both or all position. In an emergency, another engine's battery can be used to start an engine with a dead battery.

Battery Isolators. Isolators can be used to charge an auxiliary battery used for powering accessories in the boat. They should not be used to charge the battery of another engine in the boat unless the type of isolator is specifically designed for this purpose.

Generators. The generator's battery should be considered another engine's battery.

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Notes:

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Table of Contents

Section 5 - Storage

Cold Weather (Freezing Temperature), Seasonal Storage,

and Extended Storage.......................................................... 62

Cold Weather (Freezing Temperature) Storage............ 62

Preparing Your Power Package for Seasonal or

Extended Storage.......................................................... 62

Seasonal Storage.......................................................... 63

Extended Storage Instructions.......................................64

Battery........................................................................... 64

Recommissioning................................................................. 64

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Cold Weather (Freezing Temperature), Seasonal Storage, and Extended Storage

IMPORTANT: Mercury Marine strongly recommends that this service be performed by a Mercury Diesel authorized repair facility. Damage caused by freezing is not covered by the Mercury Marine Limited Warranty.

NOTICE

NOTE: As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open the seacock or unplug and reconnect the water inlet hose before starting the engine.

A boat is considered to be in storage whenever it is not in operation. The amount of time that the power package is not operated may be for a brief period, such as during a day, overnight, for a season, or for an extended period of time. Certain precautions and procedures must be observed to protect the power package from freeze damage, corrosion damage, or both types of damage during storage.

Freeze damage can happen when water trapped in the seawater cooling system freezes. For example, after operating the boat, exposure to freezing temperatures for even a brief period of time could result in freeze damage.

Corrosion damage is the result of saltwater, polluted water, or water with a high mineral content trapped in the seawater cooling system. Saltwater should not stay in an engine's cooling system for even a brief storage time; drain and flush the seawater cooling system after each outing.

Cold weather operation refers to operating the boat whenever the possibility of freezing temperatures exists. Likewise, cold weather (freezing temperature) storage refers to whenever the boat is not being operated and the possibility of freezing temperatures exists. In such cases, the seawater section of the cooling system must be completely drained immediately after operation.

Seasonal storage refers to when the boat is not being operated for one month or more. The length of time varies depending on the geographic location of the boat in storage. Seasonal storage precautions and procedures include all of the steps for cold weather (freezing temperature) storage and some additional steps that must be taken when storage will last longer than the short time of cold weather (freezing temperature) storage.

Extended storage means storage for a period of time that may last for several seasons or longer. Extended storage precautions and procedures include all of the steps for cold weather (freezing temperature) storage and seasonal storage plus some additional steps.

Refer to the specific procedures in this section related to the conditions and the length of storage for your application.

Cold Weather (Freezing Temperature) Storage

NOTICE

NOTE:

As a precautionary measure, attach a tag to the key switch or steering wheel of the boat reminding the operator to open

the seacock or unplug and reconnect the water inlet hose before starting the engine.

Read all precautions and perform all procedures found in Draining the Seawater System and drain the seawater section of the cooling system.

2. Place a caution tag at the helm advising the operator to unplug and connect the water inlet hose or open the seacock, if equipped, before operating the boat.

3. For additional assurance against freezing and corrosion fill the seawater cooling system with a mixture of propylene glycol antifreeze and tap water. See Seasonal Storage Instructions in this section.

Preparing Your Power Package for Seasonal or Extended Storage

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

IMPORTANT: If the boat has already been removed from the water, supply water to the water inlet holes before starting the engine. Follow all warnings and flushing attachment procedures stated in Flushing the Seawater System.

1. Supply cooling water to the water inlet holes or seawater pump inlet.

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2. Start the engine and operate until it reaches normal operating temperature.

3. Stop the engine.

4. Change the engine oil and filter.

5. Start the engine and run for about 15 minutes. Check for oil leaks.

Flush the seawater cooling system. See Flushing the Seawater System.

Seasonal Storage

Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended Storage.

Read all precautions and perform all procedures found in Draining the Seawater System and drain the seawater section of the cooling system.

NOTICE

Water trapped in the seawater section of the cooling system can cause corrosion or freeze damage. Remove the boat from the water to drain the seawater section of the cooling system immediately after operation or before any length of storage in freezing temperatures.

IMPORTANT: We recommend the use of propylene glycol antifreeze in the seawater section of the cooling system for cold weather (freezing temperature), seasonal storage, or extended storage. Make sure that the propylene glycol antifreeze contains a rust inhibitor and is recommended for use in marine engines. Be certain to follow the propylene glycol manufacturer's recommendations.

3. Fill a container with approximately 5.6 L (6.0 US qt) of propylene glycol antifreeze and tap water mixed to manufacturer's

recommendation to protect the engine to the lowest temperature to which it will be exposed during cold weather or extended storage.

4. Disconnect the seawater inlet hose from the seawater pump. Using an adapter, if required, temporarily connect an

appropriate length piece of hose to seawater pump and place the other end of the hose into the container of propylene glycol antifreeze and tap water.

Typical

a - Seawater pump b - Temporary hose c - Container of propylene

glycol antifreeze and tap water

IMPORTANT: Discharge of propylene glycol into the environment may be restricted by law. Dispose of propylene glycol in accordance with federal, state, and local requirements.

5. Start the engine and operate at idle speed until the antifreeze mixture has been pumped into the engine seawater cooling system.

6. Stop the engine.

7. Remove the temporary hose from the seawater pump.

8. Clean the outside of the engine and repaint any areas required with primer and spray paint. After the paint has dried, coat the engine with the specified corrosion inhibiting oil or equivalent.

Description Corrosion Guard Light gray primer 92‑802878‑52 Mercury Diesel White 8M0108939 Mercury Phantom Black Shift plate and air filter housing 92‑802878Q1

Where Used Part Number

Outside of engine

92‑802878‑55

90-8M0113986 eng DECEMBER 2015 Page 63

Page 72

Section 5 - Storage

9. Your Mercury Diesel authorized repair facility should now perform all checks, inspections, lubrications, and fluid changes outlined in Maintenance Schedules.

10. Follow the battery manufacturer's instructions for storage and store the battery.

Extended Storage Instructions

IMPORTANT: Mercury recommends that this service be performed by a Mercury Diesel authorized repair facility.

Read all precautions and perform all procedures found in Preparing Your Power Package for Seasonal or Extended Storage.

Read all precautions and perform all procedures found in Draining the Seawater System.

Read all precautions and perform all procedures found in Seasonal Storage Instructions. IMPORTANT: The seawater pump impeller material can be damaged by prolonged exposure to direct sunlight.

4. Remove the seawater pump impeller and store away from direct sunlight. Refer to a Mercury Diesel authorized repair facility for additional information and service.

5. Place a caution tag at the instrument panel and in the engine compartment stating that the seawater pump is out and not to operate the engine.

Battery

Follow the battery manufacturer's instructions for storage.

Recommissioning

NOTE: Discharge of propylene glycol into the environment may be restricted by law. Contain and dispose of propylene glycol in accordance with federal, state, and local laws and guidelines.

1. On engines prepared for extended storage, have a Mercury Diesel authorized repair facility install the seawater pump impeller, if it was removed for storage.

On engines that were prepared for cold weather (freezing temperature), seasonal, or extended storage, refer to Draining the Seawater System and drain the propylene glycol into a suitable container. Dispose of the propylene glycol in accordance with federal, state, and local laws and guidelines.

3. Ensure that all cooling system hoses are in good condition, connected properly, and clamped tightly. Verify that all drain valves and drain plugs are installed and tight.

4. Inspect all drive belts.

Perform all lubrication and maintenance specified for completion according the Maintenance Schedules, except items that were performed at time of engine service.

6. Fill the fuel tanks with fresh diesel fuel. Do not use old fuel. Check the general condition of the fuel lines and inspect the connections for leaks.

7. Replace the water‑separating fuel filter or filters (some engines may have more than one).

CAUTION

Disconnecting or connecting the battery cables in the incorrect order can cause injury from electrical shock or can damage the electrical system. Always disconnect the negative (‑) battery cable first and connect it last.

8. Install a fully charged battery. Clean the battery cable clamps and terminals. Reconnect the cables (refer to the CAUTION listed above). Secure each cable clamp when connecting. Coat terminals with a battery terminal anti‑corrosion spray to help retard corrosion.

Perform all checks in the Starting Procedure column found in the Operation Chart. Refer to the On the Water section.

NOTICE

Without sufficient cooling water, the engine, the water pump, and other components will overheat and suffer damage. Provide a sufficient supply of water to the water inlets during operation.

10. Supply cooling water to the water inlet openings.

11. Start the engine and closely observe instrumentation. Ensure that all systems are functioning correctly.

12. Carefully inspect the engine for fuel, oil, fluid, water, and exhaust leaks.

13. Check the steering system, shift, and throttle control for proper operation.

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Page 73

Table of Contents

Section 6 - Troubleshooting

Diagnosing Electronically Controlled Fuel System Problems

.............................................................................................. 66

Troubleshooting Charts........................................................ 66

Starter Motor Will Not Crank Engine, or Cranks Slow... 66

Engine Will Not Start, or Is Hard to Start....................... 66

Engine Runs Rough, Misses, or Backfires.................... 66

Poor Performance..........................................................66

Incorrect Engine Temperature....................................... 67

Low Engine Oil Pressure............................................... 67

Battery Will Not Charge................................................. 67

Remote Control Operates Hard, Binds, Has Excessive

Free‑play, or Makes Unusual Sounds........................... 67

90-8M0113986 eng DECEMBER 2015 Page 65

Page 74

Section 6 - Troubleshooting

Diagnosing Electronically Controlled Fuel System Problems

A Mercury Diesel authorized repair facility has the proper service tools for diagnosing problems on electronically controlled fuel systems. The engine control module (ECM) on these engines has the ability to detect problems with the system when they occur, and store a trouble code in the ECM's memory. This code can then be read later by a service technician using a special diagnostic tool.

Troubleshooting Charts

Starter Motor Will Not Crank Engine, or Cranks Slow

Possible Cause Remedy Battery switch turned off. Turn switch on. Remote control not in neutral position. Position control lever in neutral. Open circuit breaker or blown fuse. Check and reset circuit breaker or replace fuse.

Loose or dirty electrical connections or damaged wiring.

Bad battery. Test and replace if bad.

Engine Will Not Start, or Is Hard to Start

Check all electrical connections and wires (especially battery cables). Clean and tighten faulty connection.

Possible Cause Lanyard stop switch activated. Check lanyard stop switch. Improper starting procedure. Read starting procedure. Empty fuel tank or fuel shut‑off valve closed. Fill tank or open valve. Throttle not operating properly. Check the throttle for freedom of movement.

Faulty electrical stop‑circuit.

Clogged fuel filters. Replace fuel filters. Stale or contaminated fuel. Drain tank. Fill with fresh fuel.

Fuel line or tank vent line kinked or clogged.

Air in fuel injection system. Purge fuel injection system. Faulty wire connections. Check wire connections.

Electronic fuel system fault.

Have a Mercury Diesel authorized repair facility service the electrical stop circuit.

Replace kinked lines or blow out the lines with compressed air to remove obstruction.

Have the electronic fuel system checked by a Mercury Diesel authorized repair facility.

Remedy

Engine Runs Rough, Misses, or Backfires

Possible Cause

Throttle not operating properly. Check the throttle for binding or an obstruction.

Idle speed too low.

Clogged fuel or air filters. Replace fuel or air filters. Stale or contaminated fuel. If fuel is contaminated, drain tank. Fill with fresh fuel.

Kinked or clogged fuel line or fuel tank vent line.

Air in fuel system. Purge fuel injection system.

Electronic fuel system faulty.

Have idle speed checked and adjusted by a Mercury Diesel authorized repair facility.

Replace kinked lines or blow out lines with compressed air to remove obstruction.

Have electronic system checked by a Mercury Diesel authorized repair facility.

Remedy

Poor Performance

Possible Cause Throttle not fully open. Inspect throttle cable and linkages for proper operation. Damaged or improper propeller. Replace propeller. See a Mercury Diesel authorized repair facility. Excessive bilge water. Drain and check for cause of entry.

Page 66 90-8M0113986 eng DECEMBER 2015

Remedy

Page 75

Section 6 - Troubleshooting

Possible Cause Remedy Boat overloaded or improperly distributed. Reduce load or redistribute more evenly. Boat bottom fouled or damaged. Clean or repair as necessary. Electronic fuel system fault. Have electronic fuel system checked by a Mercury Diesel authorized repair facility.

Incorrect Engine Temperature

Possible Cause Remedy Water inlet or seacock closed. Open. Drive belt loose or in poor condition. Replace or adjust belt. Seawater pickups or sea strainer obstructed. Remove obstruction. Faulty thermostat. Replace. See a Mercury Diesel authorized repair facility.

Coolant level low in closed cooling section.

Heat exchanger cores plugged with foreign material.

Loss of pressure in closed cooling section.

Faulty seawater pickup pump. Repair. See a Mercury Diesel authorized repair facility.

Seawater discharge restricted or plugged.

Seawater inlet hose kinked (restricted). Position hose to prevent kinking (restriction). Use of improperly designed hose on inlet side of

seawater pump allowing it to collapse. Faulty thermostats. Replace. See a Mercury Diesel authorized repair facility.

Check for cause of low coolant level and repair. Fill system with proper coolant solution.

Clean heat exchanger. See a Mercury Diesel authorized repair facility.

Check for leaks. Clean, inspect, and test pressure cap. See a Mercury Diesel authorized repair facility.

Clean exhaust elbows. See a Mercury Diesel authorized repair facility.

Replace hose with wire reinforced design.

Low Engine Oil Pressure

Possible Cause Faulty senders. Have system checked by a Mercury Diesel authorized repair facility. Insufficient oil in crankcase. Check and add oil. Excessive oil in crankcase (causing it to

become aerated).

Diluted or improper viscosity oil.

Check and remove required amount of oil. Check for cause of excessive oil (improper filling).

Change oil and oil filter, using correct grade and viscosity oil. Determine cause for dilution (excessive idling).

Remedy

Battery Will Not Charge

Possible Cause

Excessive current draw from battery. Turn off non‑essential accessories.

Check all associated electrical connections and wires (especially

Loose or dirty electrical connections or damaged wiring.

Alternator drive belt loose or in poor condition. Replace or adjust. Unacceptable battery condition. Test battery.

battery cables). Clean and tighten faulty connections. Repair or replace damaged wiring.

Remedy

Remote Control Operates Hard, Binds, Has Excessive Free‑play, or Makes Unusual Sounds

Possible Cause

Insufficient lubrication on shift and throttle linkage fasteners.

Obstruction in the shift or throttle linkages. Remove the obstruction.

Loose or missing shift and throttle linkages.

Shift or throttle cable kinked.

Lubricate.

Check all throttle linkages. If any are loose or missing, see a Mercury Diesel authorized repair facility immediately.

Straighten cable or have a Mercury Diesel authorized repair facility replace cable if damaged beyond repair.

Remedy

90-8M0113986 eng DECEMBER 2015 Page 67

Page 76

Section 6 - Troubleshooting

Possible Cause Remedy

Improper shift cable adjustment. Have adjustment checked by a Mercury Diesel authorized repair facility.

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Section 7 - Customer Assistance Information

Table of Contents

Section 7 - Customer Assistance Information

Owner Service Assistance.................................................... 70

Local Repair Service .................................................... 70

Service Away From Home ............................................ 70

Stolen Power Package ................................................. 70

Attention Required After Submersion ........................... 70

Replacement Service Parts .......................................... 70

Parts and Accessories Inquiries ............................ 70

Resolving a Problem .................................................... 70

Contact Information for Mercury Marine Customer

Service ......................................................................... 71

Customer Service Literature................................................. 71

English Language ......................................................... 71

Other Languages .......................................................... 72

Ordering Literature............................................................... 72

United States and Canada ........................................... 72

Outside the United States and Canada ........................ 72

90-8M0113986 eng DECEMBER 2015 Page 69

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Section 7 - Customer Assistance Information

Owner Service Assistance

Local Repair Service

If you need service for your Mercury MerCruiser‑powered boat, take it to your authorized dealer. Only authorized dealers specialize in Mercury MerCruiser products and have factory‑trained mechanics, special tools and equipment, and genuine Quicksilver parts and accessories to properly service your engine.

NOTE: Quicksilver parts and accessories are engineered and built by Mercury Marine specifically for Mercury MerCruiser sterndrives and inboards.

Service Away From Home

If you are away from your local dealer and the need arises for service, contact the nearest authorized dealer. If, for any reason, you cannot obtain service, contact the nearest regional service center. Outside the United States and Canada, contact the nearest Marine Power International service center.

Stolen Power Package

If your power package is stolen, immediately inform the local authorities and Mercury Marine of the model and serial numbers and to whom the recovery is to be reported. This information is maintained in a database at Mercury Marine to aid authorities and dealers in recovery of stolen power packages.

Attention Required After Submersion

1. Before recovery, contact an authorized Mercury MerCruiser dealer.

2. After recovery, immediate service by an authorized Mercury MerCruiser dealer is required to reduce the possibility of serious engine damage.

Replacement Service Parts

WARNING

Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.

Marine engines are expected to operate at or near full throttle for most of their life. They are also expected to operate in both fresh and saltwater environments. These conditions require numerous special parts. Exercise care when replacing marine engine parts because specifications are different from those of the standard automotive engine. For example, one of the most important special replacement parts is the cylinder head gasket. Marine engines cannot use steel‑type automotive head gaskets because saltwater is highly corrosive. A marine engine head gasket uses special materials to resist corrosion.

Because marine engines must be capable of running at or near maximum RPM much of the time, they also have special valve springs, valve lifters, pistons, bearings, camshafts, and other heavy‑duty moving parts.

Mercury MerCruiser marine engines have other special modifications to provide long life and dependable performance.

Parts and Accessories Inquiries

Direct any inquiries concerning Quicksilver replacement parts and accessories to your local authorized dealer. The dealer has the necessary information to order parts and accessories for you. Only authorized dealers can purchase genuine Quicksilver parts and accessories from the factory. Mercury Marine does not sell to unauthorized dealers or retail customers. When inquiring about parts and accessories, the dealer requires the engine model and serial numbers to order the correct parts.

Resolving a Problem

Satisfaction with your Mercury MerCruiser product is important to your dealer and to us. If you ever have a problem, question, or concern about your power package, contact your dealer or any authorized Mercury MerCruiser dealership. If you need additional assistance:

1. Talk with the dealership's sales manager or service manager. Contact the owner of the dealership if the sales manager and service manager have been unable to resolve the problem.

2. If your question, concern, or problem cannot be resolved by your dealership, please contact a Mercury Marine Service Office for assistance. Mercury Marine will work with you and your dealership to resolve all problems.

The following information will be needed by Customer Service:

• Your name and address

• Daytime telephone number

• Model and serial numbers for your power package

• The name and address of your dealership

Page 70 90-8M0113986 eng DECEMBER 2015

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Section 7 - Customer Assistance Information

• Nature of the problem

Contact Information for Mercury Marine Customer Service

For assistance, call, fax, or write. Please include your daytime telephone number with mail and fax correspondence.

United States, Canada

Telephone

Fax

Website www.mercurymarine.com

Australia, Pacific Telephone +61 3 9791 5822 Brunswick Asia Pacific Group

Fax +61 3 9706 7228

Europe, Middle East, Africa Telephone +32 87 32 32 11 Brunswick Marine Europe

Fax +32 87 31 19 65

English +1 920 929 5040 Français +1 905 636 4751

English +1 920 929 5893 Français +1 905 636 1704

41–71 Bessemer Drive Dandenong South, Victoria 3175 Australia

Parc Industriel de Petit-Rechain B-4800 Verviers, Belgium

Mercury Marine W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939

Mexico, Central America, South America, Caribbean Telephone +1 954 744 3500 Mercury Marine

11650 Interchange Circle North

Fax +1 954 744 3535

Japan Telephone +072 233 8888 Kisaka Co., Ltd.

4-130 Kannabecho Sakai-shi Sakai-ku

Fax +072 233 8833

Asia, Singapore Telephone +65 65466160 Brunswick Asia Pacific Group

Fax +65 65467789

5900984 Osaka, Japan

T/A Mercury Marine Singapore Pte Ltd 29 Loyang Drive Singapore, 508944

Miramar, FL 33025 U.S.A.

Customer Service Literature

English Language

English language publications are available from: Mercury Marine Attn: Publications Department W6250 Pioneer Road P.O. Box 1939 Fond du Lac, WI 54936-1939

Outside the United States and Canada, contact the nearest Mercury Marine or Marine Power International Service Center for further information.

When ordering be sure to:

• List your product, model, year, and serial numbers.

• Check the literature and quantities you want.

• Enclose full remittance in check or money order (NO COD).

90-8M0113986 eng DECEMBER 2015 Page 71

Page 80

Section 7 - Customer Assistance Information

Other Languages

To obtain an Operation, Maintenance and Warranty Manual in another language, contact the nearest Mercury Marine or Marine Power International Service Center for information. A list of part numbers for other languages is provided with your power package.

Ordering Literature

Before ordering literature, have the following information about your power package available:

Model Serial Number Horsepower Year

United States and Canada

For additional literature for your Mercury Marine power package, contact your nearest Mercury Marine dealer or contact:

Mercury Marine

Telephone Fax Mail

Mercury Marine

(920) 929‑5110

(USA only)

Outside the United States and Canada

Contact your nearest Mercury Marine authorized service center to order additional literature that is available for your particular power package.

(920) 929‑4894

(USA only)

Attn: Publications Department

P.O. Box 1939

Fond du Lac, WI 54936-1939

Mercury Marine Submit the following order form with payment to:

Ship To: (Copy this form and print or type–This is your shipping label)

Name

Address

City, State, Province

ZIP or postal code

Country

Quantity Item Stock Number Price Total

Attn: Publications Department

W6250 Pioneer Road

P.O. Box 1939

Fond du Lac, WI 54936-1939

. . . . . . . . . .

Total Due .

Page 72 90-8M0113986 eng DECEMBER 2015

Page 81

Section 8 - Maintenance Log

Table of Contents

Scheduled Maintenance Log................................................ 74 Vessel Maintenance Notes................................................... 75

90-8M0113986 eng DECEMBER 2015 Page 73

Page 82

Section 8 - Maintenance Log

Scheduled Maintenance Log

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

100 Hours

Signature

200 Hours

Signature

300 Hours

Signature

Date

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

Actual Hours Service Notes

Dealer Name

400 Hours

Signature

500 Hours

Signature

600 Hours

Signature

Date

Page 74 90-8M0113986 eng DECEMBER 2015

Page 83

Section 8 - Maintenance Log

Vessel Maintenance Notes

Record all general maintenance performed on your power package here. Save all work orders and receipts.

Date

Engine

Hours

Maintenance Completed Servicing Dealer

90-8M0113986 eng DECEMBER 2015 Page 75

Page 84

Page 85

www.mercurymarine.com.au

41-71 Bessemer Drive

Dandenong South, Victoria 3175 Australia

www.mercurymarine.com

P.O. Box 1939

Fond du Lac, WI 54936-1939 USA

www.brunswick-marine.com

Parc Industriel de Petit-Rechain

B-4800 Verviers, Belgium

Printed in U.S.A.

90-8M0113986 NOVEMBER 2015

Mercury 92-8M0069603, 92-8M0070979, MerCruiser Diesel Inboard 2.8L, MerCruiser Diesel Inboard 4.2L Maintance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Welcome

Read This Manual Thoroughly

Notice

2.0L Diesel Engine Inboard Models

Warranty Message

Copyright and Trademark Information

Identification Records

TABLE OF CONTENTS

Features and Controls

Warning Horn Signals

Instrumentation

VesselView

SmartCraft Speedometer, Tachometer, and Digital Gauges

System Link Digital Gauges

Switches

Emergency Stop Switch

Lanyard Stop Switch

Keep the Lanyard Stop Switch and Lanyard Cord in Good Operating Condition

Digital Throttle and Shift

Remote Controls

Panel Mount Features

Console Mount Features

Engine Electrical System Overload Protection

Vessel Integration Panel (VIP) Overload Protection

Engine Guardian System

Identification

Specifications Label

Data Label Location

Engine Data Label

Technodrive Transmissions

Safe Boating Recommendations

Carbon Monoxide Exposure

Be Alert To Carbon Monoxide Poisoning

Stay Clear of Exhaust Areas

Good Ventilation

Poor Ventilation

Important Operation Information

Launching

Duty Cycle Rating Requirements

Operation Chart

Freezing Temperature and Cold Weather Operation

Drain Plug and Bilge Pump

Starting, Shifting, and Stopping

Before Starting the Engine

Important Information—SmartStart

Starting a Cold Engine

Engine Warm Up

Starting a Warm Engine

Shifting

Engine Shut Down (Stopping)

Protecting People in the Water

While Boat is in Operation

While the Boat is Stationary

Passenger Safety In Pontoon Boats and Deck Boats

Boats Having An Open Front Deck

Wave and Wake Jumping

Impact With Underwater Hazards

Conditions Affecting Operation

Weight Distribution (Passengers and Gear) Inside the Boat

Bottom of Boat

Elevation and Climate

Propeller Selection

Getting Started

20-Hour Break-In Period

After the 20-Hour Break-In Period

End of First Season Checkup

Fuel Requirements

Diesel Fuel in Cold Weather

Antifreeze/Coolant

Engine Oil

Fluid Specifications

Engine

Transmission

Approved Paints

Owner and Operator Responsibilities

Dealer Responsibilities